Boiler Manual

Transcript

Boiler Manual Incorporating: User Instructions Installation Instructions Commissioning Instructions Maintenance Instructions Commissioning Certificate Service Record High Efficiency Condensing Gas Boilers Model covered by this manual: G-Series GC29B Gas combi boiler SEDBUK TR05A153.B1107 TR05A153.B1107 CONTENTS 1 USER INSTRUCTIONS 1.1 Boiler controls 1.1.1 Control panel layout 1.1.2 Operating the appliance 1.1.3 Operating modes 1.2 Topping up the system (Error Code H20) 1.3 If you smell gas 2 GENERAL INFORMATION 2.1 2.2 2.3 3 General warnings Information Product conformity TECHNICAL CHARACTERISTICS 3.1 Technical data 3.2 Dimensions 3.3 Internal components 3.4 Function diagram 3.5 Circulation pump performance curves 3.6 Control panel, display and appliance operation 3.6.1 Layout 3.6.2 Boiler operation 3.6.3 Operating modes 3.6.4 Function codes 4 INSTALLATION 4.1 Reference standards 4.2 Unpacking 4.3 Installing the boiler 4.3.1 Compartment ventilation 4.4 Water connections 4.4.1 Domestic hot water circuit 4.4.2 Central heating circuit 4.4.3 Filling the central heating system 4.5 Condensate drain 4.6 Gas connection 4.7 Electrical connections 4.7.1 General warnings 4.7.2 Power supply 4.8 Flue connections 4.8.1 Flue position 4.8.2 Horizontal coaxial balanced flue – Ø 60/100 (Kit K) 4.8.3 Horizontal coaxial balanced flue – Ø 80/125 4.8.4 Vertical coaxial balanced flue – Ø 60/100 (Kit V) 4.8.5 Vertical coaxial balanced flue – Ø 80/125 4.8.6 Flue diaphragm installation – Coaxial balanced flue kits 4.8.7 Flue diaphragm adjustment – Ø 60/100 Coaxial balanced flues 4.8.8 Flue diaphragm adjustment – Ø 80/125 Coaxial balanced flues 4.8.9 Twin Pipe flue system – Ø 80/80 (Kit H) 4.8.10 Flue diaphragm installation – Twin pipe flue Kit H 4.8.11 Flue diaphragm adjustment – Twin pipe flue Kit H TR05A153.B1107 4 4 4 4 4 5 5 6 6 6 8 9 9 10 11 12 13 14 14 14 15 15 16 16 17 18 18 19 19 20 20 21 22 23 23 24 25 26 27 28 29 30 31 32 32 33 34 35 CONTENTS 5 COMMISSIONING 5.1 General warnings 5.2 Filling the system 5.3 Flushing the system 5.4 Filling the condensate trap 5.5 Starting the boiler 5.6 Checking gas pressures 5.6.1 Working pressure (at meter and appliance) 5.6.2 Mechanical minimum gas pressure 5.6.3 Mechanical maximum gas pressure 5.6.4 Maximum and minimum CH gas pressures 5.6.5 Ignition sequence gas pressures 5.7 Control parameters 5.7.1 Accessing the parameters menu 5.7.2 Adjusting the parameters 5.8 Gas data 5.8.1 Technical reference tables 5.9 Converting to a different gas type 6 MAINTENANCE 6.1 General warnings 6.2 Boiler inspection 6.3 Accessing the boiler 6.3.1 Front panel removal 6.3.2 Side panel removal 6.3.3 Control panel access 6.4 Draining the central heating system 6.5 Flushing the central heating system 6.6 Draining the domestic hot water system 6.7 Maintenance operations 6.7.1 Primary heat exchanger and burner unit 6.7.2 DHW heat exchanger 6.7.3 Ignition and ionisation electrodes 6.7.4 Safety thermostat 6.7.5 Heating sensor 6.7.6 Gas valve 6.7.7 Electric fan 6.7.8 Expansion vessel 6.7.9 Circulating pump motor body 6.7.10 3-way diverter valve 6.7.11 Printed circuit board (PCB) 6.7.12 Secondary heat exchanger 6.8 Internal wiring 6.9 Troubleshooting 6.9.1 Error codes 6.10 Parts lists 6.10.1 Main components 6.10.2 MULTIPLEX unit 7 OPTIONAL CONTROLS 7.1 TR05A153.B1107 External controls, programmers and room thermostats 36 36 37 37 38 38 39 39 40 40 40 41 42 43 44 48 48 49 50 50 50 51 51 51 51 52 52 52 53 54 55 55 56 56 56 57 57 58 58 59 60 61 62 62 63 63 64 66 66 CONTENTS 7.1.1 Appliance connections 7.1.2 S-Plan wiring schematic 7.2 Weather compensating controls 7.2.1 Fitting the outside sensor 7.2.2 Controlling the appliance TR05A153.B1107 66 67 68 68 68 GENERAL INFORMATION 1 USER INSTRUCTIONS 1.1 Boiler controls 9 8 1.1.1 Control panel layout 1. ON/OFF button TIME ON OFF 2. Central Heating Control knob 3. Hot Water Control knob 4. DISPLAY button 5. S SERVICE button 6. MODE button MODE ON / OFF 7. Mains supply terminal board 1 8. Digital LCD display 9. Programmer location 2 3 4 5 6 7 Figure 1: Control Panel 1.1.2 Operating the appliance Operation Instruction Switching the boiler on Press the ON/OFF button (1) Selecting the operating mode (see Section 1.1.3 below) Press the - either the Adjusting the Central Heating temperature Turn the Central Heating Control knob (2): - the temperature setting will appear on the display (if you have an Outside Sensor fitted, see Section 7.2.2) Adjusting the Hot Water temperature Turn the Hot Water Control knob (3): - the temperature setting will appear on the display Switching the boiler off Press the ON/OFF button (1) Table 1: Control panel display 1.1.3 Operating modes Heating Only Mode Hot Water Only Mode & TR05A153.B1107 Heating & Hot Water Mode 4 MODE button (6): , or & Icons will appear on the display GENERAL INFORMATION 1.2 Topping up the system (Error Code H20) If the water pressure in the central heating circuit falls below 0.3 bar, the boiler will go to lock out (stop working) and Error Code H2O will appear on the display. This could be caused be a leak in the system, if air is bled from a radiator or if a radiator is replaced. The system will then need to be topped up. To top up the system: • Let the boiler and radiators cool down; • Connect the filling loop (usually located near the boiler); • Open the filling loop valve (or valves); • Fill the system until the pressure gauge (located on the underside of the boiler) reads 1 bar; • Switch the boiler off then on again using the ON/OFF button on the Control Panel; • Check that Error Code H2O is no longer shown on the Control Panel display; • Close the filling loop valve (or valves) and disconnect the filling loop. The boiler should now fire and continue to work normally. If a lot of water was required to fill the system (such as after a radiator is replaced) it may be necessary to repeat the process a few times over a period. 1.3 If you smell gas • DO NOT operate any electric switches, telephones or any other equipment that may cause sparks; • Open doors and windows immediately to create a current of air and ventilate the room; • Shut off the main gas supply valve (either at the meter or on the cylinder in the case of bottled gas); • From a safe location, telephone the following 24 hour gas emergency numbers: Great Britain Northern Ireland Republic of Ireland TR05A153.B1107 0800 111 999 0800 002 001 1850 20 50 50 5 GENERAL INFORMATION 2 GENERAL INFORMATION 2.1 General warnings This appliance must only be installed and commissioned by professionally qualified personnel in accordance with current laws and standards and in line with the manufacturer’s instructions. In the United Kingdom, the installation must be carried out by a CORGI Registered Installer. To check for authorised qualified engineers please contact CORGI on 0870 401 2300. The installation must be carried out in accordance with the relevant requirements of: - The Gas Safety Regulations; - The appropriate Building Regulations – either the Building Regulations, the Building Regulations (Scotland) or the Building Regulations (Northern Ireland); - The Water Fittings Regulations or Water Byelaws in Scotland; - The current I.E.E. Wiring Regulations. Where no specific instructions are given, reference should be made to the relevant British Standards Code of Practice. In the Republic of Ireland, the installation must be carried out by a competent person and in accordance with the current edition of I.E. 813 ‘Domestic Gas Installations’, the current Building Regulations and the current ETCI rules for electrical installations. The appliance must be used solely for the purpose for which it has been designed and manufactured: central heating and domestic hot water production. Any other use is deemed as improper and as such dangerous. Under no circumstances will the manufacturer be held responsible for damage or injury to persons or animals caused by errors in the installation and/or use of the appliance, or through noncompliance with current local and national standards and/or the manufacturer’s instructions. This instruction manual forms an integral and essential part of the product and must be kept with the appliance, in a safe place, available for future reference. This manual, along with the Benchmark commissioning booklet, must be left with the end user as per Regulation 29 of the HSC Gas Safety (Installation and Use) Regulations 1998. The warnings contained in this chapter have been written for the appliance user, the installer and the service engineer. This instruction manual must be read carefully as it provides information on the operation and the operating limits of the appliance. This appliance is only suitable for use in a sealed central heating system. 2.2 Information • After the removal of all the packaging, check that the appliance has not been damaged. In case of doubt, do not attempt to use the product but refer to the supplier. Packing materials (cardboard box, wooden crate, nails, staples, plastic bags, polystyrene, etc.) must not be left within reach of children as these items represent a potential hazard and must be disposed of in a responsible manner. • Before carrying out any cleaning or maintenance operations, isolate the appliance from the electricity supply by switching off at the main switch and/or any other isolating device. • Do not obstruct the air intake or flue exhaust terminals. • In the case of a fault and/or malfunction in the appliance, shut down the system. Do not interfere with or attempt to repair the appliance. Contact your commissioning engineer in the first instance or contact the Warmflow Customer Care Centre on 028 9262 1515. • Any warranty repairs to the appliance must be carried out exclusively by the manufacturer’s authorised service centre using original spare parts. Non-compliance with this requirement may compromise the safety of the appliance and invalidate the warranty. In order to guarantee the efficiency of the appliance and its correct operation, it must be serviced regularly by professionally qualified personnel in line with the manufacturer’s instructions. TR05A153.B1107 6 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. • Should there be a smell of gas present in the room where the appliance is installed, DO NOT attempt to activate any electric switches, telephones or any other equipment that may cause sparks. Open doors and windows immediately to create a current of air and ventilate the room. Shut-off the main gas supply valve (either at the meter or on the cylinder in the case of bottled gas), then telephone the following 24 hour gas emergency numbers: Great Britain Northern Ireland Republic of Ireland 0800 111 999 0800 002 001 1850 20 50 50 • Before starting the boiler for the first time, make sure that it is connected to a water supply and central heating system compatible with its performance characteristics. • Check the technical data displayed on the packing and on the data plate located on the inside of the front casing. Also check that the burner is appropriate for the type of gas to be used. • Make sure that the pipes and fittings used for the gas service are perfectly tight and that there are no gas leaks. • Prior to start-up, the central heating pipes should be flushed to remove any residues that could compromise the operation of the appliance. • The appliance can be regarded as being electrically safe when it has been connected to an effective earth system installed in accordance with the requirements of current safety standards. This fundamental safety requirement must be checked and verified. In case of doubt, have the electrical system checked by a qualified electrician. The manufacturer will not be held liable for any damage or injury caused as a result of an ineffective or non-existent earth system. • The domestic power supply must be checked by a qualified electrician to ensure that it can support the maximum power absorption of the appliance, as indicated on the appliance data plate (positioned on the inside of the front casing). In particular, make sure that the cable ratings are adequate for the power absorbed. • Do not use adapters; multiple sockets or extension leads to connect the appliance to the mains power supply. • The appliance must be connected to the mains power supply through an appropriate electrical isolator in accordance with the current wiring regulations. • 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.) TR05A153.B1107 7 GENERAL INFORMATION 2.3 Product conformity Warmflow declares that all its products are manufactured to a high specification and in compliance with the relevant standards. All Warmflow gas boilers are CE certified and possess technical and functional characteristics that comply with the following directives and standards: GAS APPLIANCES DIRECTIVE 90/396 CEE for CE compliance LOW VOLTAGE DIRECTIVE 73/23 CEE ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 89/336 CEE BOILER EFFICIENCY DIRECTIVE 92/42 CEE UNI EN 297 for GAS-FIRED CENTRAL HEATING BOILERS TYPE B OF NOMINAL HEAT INPUT ≤ 70 kW EN 483 for GAS-FIRED CENTRAL HEATING BOILERS TYPE C OF NOMINAL HEAT INPUT ≤ 70 kW UNI EN 677 for GAS-FIRED CENTRAL HEATING BOILERS: SPECIFIC REQUIREMENTS FOR CONDENSING BOILERS WITH NOMINAL HEAT INPUT ≤ 70 kW Warmflow will not be responsible for the consequences of non-observance of the instructions contained within this manual where actions not specifically described herein are undertaken. TR05A153.B1107 8 TECHNICAL CHARACTERISTCS 3 TECHNICAL CHARACTERISTICS 3.1 Technical data Model GC29B Appliance Type Appliance Category Heat Input max Heat Input min Heat Output max (50/30°) Heat Output max - 80/60°C (Non-condensing) Heat Output min - 80/60°C (Non-condensing) Efficiency 100% (full load 50/30°) Efficiency 30% (partial load 50/30°) Efficiency 100% (full load 80/60°) Efficiency 30% (partial load 80/60°) GAS DIRECTIVE 92/42/ECC - Efficiency marking NOx class (European Standard UNI EN 297 – pr A5) SEDBUK kW kW kW kW kW % % % % stars class band C12 C32 C42 C52 C82 II2H3+ 30 18 30.87 29.01 16.87 102.9 99.1 96.7 95.1 4 2 B Central Heating (CH) Circuit CH temperature setting (min-max) Max. CH working temperature Expansion vessel capacity Max. working pressure Min. working pressure °C °C litres bar bar 30-80 80 10 3 0.3 °C bar bar litres/min litres/min litres/min 35-60 6 0.5 16.63 13.86 11.89 mm mm mm kg 450 830 330 50 Ø Ø Ø Ø Ø 3/4” (22mm tail supplied) 3/4” (22mm tail supplied) 1/2” (15mm tail supplied) 1/2” (15mm tail supplied) 3/4” (22mm tail supplied) Ø mm m Ø mm m Ø mm m Ø mm m Ø mm m 60/100 4 80/125 5 60/100 4 80/125 5 80/80 40 mbar m3/h 20 3.17 mbar kg/h 30 2.37 mbar kg/h 37 2.33 V/Hz W IP 230/50 175 X4D Domestic Hot Water (DHW) Circuit DHW temperature setting (min-max) Max. working pressure Min. working pressure DHW flow rate at ∆T = 25°C DHW flow rate at ∆T = 30°C DHW flow rate at ∆T = 35°C Dimensions Width Height Depth Weight (net) Hydraulic Connections CH Flow connection CH Return connection Cold Water Mains connection DHW connection Gas connection Flue Systems Horizontal Concentric flue system Max. Flue length Horizontal Concentric flue system Max. Flue length Vertical Concentric flue system Max. Flue length Vertical Concentric flue system Max. Flue length Twin Pipe flue system Max. Flue length Gas Supply Natural Gas (Methane) G20 Inlet pressure Gas consumption Butane G30 Inlet pressure Gas consumption Propane G31 Inlet pressure Gas consumption Electrical Specification Power supply Electrical power consumption Electrical protection Table 2: Technical data TR05A153.B1107 9 TECHNICAL CHARACTERISTCS 3.2 Dimensions 450 830 160 TIME ON OFF MODE ON / OFF HR HWO 70 CWI 80 HF 102 130 55.5 330 325 160 224 64.5 78 G 104 226 Figure 2: Dimensions TR05A153.B1107 10 LEGEND HR HEATING RETURN 22mm HF HEATING FLOW 22mm G GAS 22mm CWI COLD WATER INLET 15mm HWO HOT WATER OUTLET 15mm CD CONDENSATE DRAIN 25mm TECHNICAL CHARACTERISTCS 3.3 Internal components 24 26 9 25 9 2 8 10 18 8 3 6 5 7 4 13 12 27 13 19 28 14 12 23 27 22 20 29 17 16 15 11 21 Figure 3: Internal components LEGEND 1. EXPANSION VESSEL 2. FLUE HOOD 3. COMBUSTION CHAMBER 4. ROOM SEALED CHAMBER BULKHEAD 5. IGNITION ELECTRODE 6. IONISATION ELECTRODE 7. BURNER 8. PRIMARY HEAT EXCHANGER 9. SECONDARY HEAT EXCHANGER 10. HEATING SAFETY THERMOSTAT 11. ELECTRONIC GAS VALVE 12. PUMP WITH AIR VENT 13. AUTOMATIC AIR VENT VALVE 14. 3 BAR PRESSURE RELIEF VALVE - HEATING CIRCUIT 15. SYSTEM DRAIN VALVE 16. WATER PRESSURE GAUGE 17. WATER PRESSURE SWITCH 18. HEATING SENSOR 19. DHW SENSOR 20. 3-WAY VALVE 21. IGNITION TRANSFORMER 22. ELECTRONIC FLOWSWITCH 23. AUTOMATIC BYPASS 24. AIR PRESSURE SWITCH 25. FAN 26. FLUE SAFETY THERMOSTAT 27. DHW EXCHANGER 28. CONDENSATE TRAP TR05A153.B1107 11 24 1 TECHNICAL CHARACTERISTCS 3.4 Function diagram LEGEND 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 26 9 2 25 1 24 8 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 18 10 3 5 6 7 4 11 19 13 12 14 23 HR Figure 4: Function diagram HR HEATING RETURN 22mm HF HEATING FLOW 22mm G GAS 22mm CWI COLD WATER INLET 15mm HWO HOT WATER OUTLET 15mm CD CONDENSATE DRAIN 25mm TR05A153.B1107 12 EXPANSION VESSEL FLUE HOOD COMBUSTION CHAMBER ROOM SEALED CHAMBER BULKHEAD IGNITION ELECTRODE IONISATION ELECTRODE BURNER PRIMARY HEAT EXCHANGER SECONDARY HEAT EXCHANGER HEATING SAFETY THERMOSTAT ELECTRONIC GAS VALVE PUMP WITH AIR VENT AUTOMATIC AIR VENT VALVE 3 BAR PRESSURE RELIEF VALVE - HEATING CIRCUIT SYSTEM DRAIN VALVE WATER PRESSURE GAUGE WATER PRESSURE SWITCH HEATING SENSOR DHW SENSOR 3-WAY VALVE IGNITION TRANSFORMER ELECTRONIC FLOWSWITCH AUTOMATIC BYPASS AIR PRESSURE SWITCH FAN FLUE SAFETY THERMOSTAT DHW EXCHANGER CONDENSATE TRAP TECHNICAL CHARACTERISTCS Head (kPa) 3.5 Circulation pump performance curves 70 60 50 III 40 II 30 I 20 10 0 0 200 400 600 800 1000 1200 1400 Flow l/h III II I Available head at maximum speed Available head at second speed Available head at minimum speed Appliance Loss Figure 5: Pump performance curves TR05A153.B1107 13 1600 TECHNICAL CHARACTERISTCS 3.6 Control panel, display and appliance operation The appliance MUST be supplied with a permanent live in order for the boiler’s protective functions to operate. These functions include frost protection, post-ventilation, pump overrun and pump & 3-way valve inactivity protection. On first connection to the power supply, the appliance must be switched on using the ON/OFF button on the control panel to activate all of the above protective features. The appliance can then be switched off but the protective features will remain active. 9 3.6.1 Layout 8 1. ON/OFF button 2. CH Control knob TIME ON OFF 3. DHW Control knob 4. DISPLAY button 5. S SERVICE button 6. MODE button MODE ON / OFF 7. Mains supply terminal board 8. Digital LCD display 9. 1 Programmer location 2 3 4 5 6 7 Figure 6: Control Panel 3.6.2 Boiler operation Mode / Control Input Display will show: Boiler switched off OFF Press ON/OFF button (to switch the boiler on) Primary circuit temperature in ºC Either , or & Icons (see Section 3.6.3) MODE button pressed Cycles through CH controls call for heat Primary circuit temperature in ºC Icon – flashes whilst CH mode is active DHW tap opened Primary circuit temperature in ºC Icon – flashes whilst DHW mode is active DISPLAY button pressed & held Outside temperature in ºC (if Outside Sensor fitted) (see Section 7.1.2) DISPLAY button pressed & held for 5 seconds DHW flow temperature in ºC CH Control knob turned CH set point temperature in ºC – displayed for 3 seconds CH Control knob turned (Outside Sensor fitted) Weather compensating control profile – displayed for 3 seconds (if Outside Sensor fitted) (see Section 7.1.2) DHW Control knob turned DHW set point temperature in ºC – displayed for 3 seconds SERVICE button pressed & held for 7 seconds Function Code 07 – flashes whilst activated (see Section 3.6.4) Boiler protection function activated (automatically) Function Code 08 or 09 – flashes whilst activated (see Section 3.6.4) Boiler locked out Error Code – flashes whilst locked out (see Section 6.9.1) Table 3: Control panel display TR05A153.B1107 14 , or & Icons (see Section 3.6.3) TECHNICAL CHARACTERISTCS 3.6.3 Operating modes Heating Only Mode Hot Water Only Mode & Heating & Hot Water Mode 3.6.4 Function codes Code Function Description Operates the boiler at maximum CH output for 15 minutes without modulation. 07 08 09 Commissioning Mode Activated by pressing and holding the S button for 7 seconds. Deactivated by switching the appliance off. CH Frost Protection Mode 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. DHW Frost Protection Mode 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 TR05A153.B1107 15 INSTALLATION INSTRUCTIONS 4 INSTALLATION 4.1 Reference standards In the United Kingdom, the installation of this appliance must be carried out by a CORGI Registered Installer. To check for authorised qualified engineers contact CORGI on 0870 401 2300. The installation must be carried out in accordance with the relevant requirements of the: - Gas Safety Regulations; The appropriate Building Regulations – either the Building Regulation, the Building Regulations (Scotland) or the Building Regulations (Northern Ireland); The Water Fittings Regulations or Water Byelaws in Scotland; The current I.E.E. Wiring Regulations. Where no specific instructions are given, reference should be made to the relevant British Standards Code of Practice. In the United Kingdom, the following Codes of Practice apply: BS 5440: Part 1 BS 5440: Part 2 BS 5546 BS 5449 BS 6700 BS 6798 BS 6891 BS 7074 BS 7593 BS 7671 Flues Air Supply 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. TR05A153.B1107 16 INSTALLATION INSTRUCTIONS 4.2 Unpacking ■ The materials (cardboard) used for packing the appliance are fully recyclable. ■ It is recommended that the packing material is only removed when the appliance is ready to be installed. The manufacturer will not be held responsible for damage caused by incorrect storage of the product. ■ Packing materials (plastic bags, polystyrene, nails, etc.) must not be left within reach of children, in that these items represent a potential hazard. A. With the packed appliance on the floor (see Figure 7), remove the staples and open out the four flaps on the end of the box; A B B. Stand the boiler up on its end as shown, supporting it from underneath; C. Lift off the box and remove all packaging. STORAGE & HANDLING Please note that prior to installation, the boiler should be stored in the horizontal position with no more than 5 boilers to a stack; C Ensure that the boilers are stored in dry conditions and be aware that the carton is a two-man lift. Figure 7: Unpacking instructions TR05A153.B1107 17 INSTALLATION INSTRUCTIONS 4.3 Installing the boiler ■ 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. Y H ■ L X A ■ 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. MINIMUM DISTANCE IN mm B ■ MXodel Y LX HY AL BH A B RKR 60 29 60 60 450 60 1000 410 200 1000 300 200 300 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 domestic hot and cold water pipes, the gas supply pipe and the central heating pipes using the fittings supplied with the boiler. 4 Install the hanging bracket then fix the boiler to the wall and connect the pipes. Figure 9: Mounting procedure 4.3.1 Compartment ventilation Where the appliance is installed in a compartment, no air vents are required. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation. TR05A153.B1107 18 INSTALLATION INSTRUCTIONS 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 circuits 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. 64.5 78 70 80 102 ■ To prevent vibration and noise coming from HR HWO G CWI the system, do not use pipes of reduced diameter, short radius elbows or severe Figure 10: Location of connections restrictions. 4.4.1 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 °Ck. It is nevertheless advisable to check the properties of the water supply and install the appropriate treatment devices where necessary. CWI Ø 22 mm G Ø 22 15 mm HR HWO Ø 15 mm Ø 22 mm The frequency of cleaning of the DHW heat Figure 11: Fittings kit exchanger depends on the hardness of the mains water supply and the presence of residual LEGEND solids or impurities, which are often present in HR HEATING RETURN the case of a new installation. If the characteristics of the mains water supply are HF HEATING FLOW such that require it to be treated, then the appropriate treatment devices must be installed, GAS G while in the case of residues, an in-line filter CWI COLD WATER INLET should be sufficient. TR05A153.B1107 HF HF The cold water supply pressure at the inlet to the boiler must be between 0.5 and 6 bar. In areas with higher water inlet pressure a pressure reducing valve must be fitted before the boiler. All DHW circuits, connections, fittings, etc. comply with all relevant standards and water supply regulations (e.g. WRAS). 55.5 22mm 22mm 22mm 15mm HWO HOT WATER OUTLET 15mm CD CONDENSATE DRAIN 25mm 19 INSTALLATION INSTRUCTIONS 4.4.2 Central heating circuit The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS 5449 and BS 6798. The system should be designed to operate with flow temperatures of up to 82°C. When designing the system, the pump head, expansion vessel size, mean radiator temperature, etc. must all be taken into account. The boiler is supplied with the following components built in:Pressure relief valve – complies with BS 6759 and set is to operate at 3 bar. The outlet connection of the pressure relief valve must be connected via a tundish to a safe visible discharge. The manufacturer will not be held responsible for flooding caused by the operation of the pressure relief valve in the case of system overpressure where adequate drainage has not been provided. Pressure gauge – indicates the system pressure. Expansion vessel – conforms to BS 7074:1 and has a volume of 10 litres. If the total system volume requires more than 10 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 System drain tap Note: A drain tap should be installed at the lowest point of the heating circuit and beneath the appliance Pressure reducing valve reccomended for inlet supplies in excess pf 3.5 bar Mains water inlet Figure 12: Central heating system layout 4.4.3 Filling the central heating system All fittings used in filling the system must be suitable for mains pressure applications. Filling of the system must be carried out in an approved manner (in the UK, refer to Guidance G24.2 and Recommendation R24.2 of the Water Regulation Guide) and in accordance with the instructions in Section 5.2. The system should be filled via a temporary filling loop connection as shown in Figure 13. After filling, the flexible hose of the filling loop must be disconnected. The filling loop should be installed such that it can be easily reconnected in order to top up the system if any water is lost (e.g. due to leakage or after replacing a radiator). Drain cocks (to BS 2879) must be fitted to the lowest points in the system to allow it to be completely drained. A corrosion inhibitor must be added to the CH circuit in order to guarantee the life of the appliance. In hard water areas, a combined corrosion inhibitor and softener must be used. The system pre-charge pressure (cold) should be 1 bar. TR05A153.B1107 Figure 13: Filling loop layout 20 INSTALLATION INSTRUCTIONS 4.5 Condensate drain Failure to install the condensate discharge pipe work correctly will affect the reliable operation of the boiler. Termination to an internal soil and vent pipe 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. 50m m per m e tre of p 2.5° Min ipe run imum fa ll 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. 450mm min Ensure the discharge of condensate complies with any national or local regulations in force. External termination via internal discharge branch e.g. sink waste - downstream 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. Boiler 5 0m m per m e tre of p ipe run 2.5° Min imum fa ll Sink Pipe must terminate above water level but below surrounding surface 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. External termination to a drain or gully Boiler Pipe must terminate above water level but below surrounding surface If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run. 50m m per m e tre of p ipe run 2.5° Min imum fa ll 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. External termination to a purpose made soak-away Boiler 500mm min 50m m p er m e tre of p ipe run 2.5° Min imum fa ll Holes in the soak-away must face away from the building Figure 14: Condensate drain configuration TR05A153.B1107 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. 21 INSTALLATION INSTRUCTIONS 4.6 Gas connection The connection to the gas supply must be carried out by professionally qualified personnel in accordance with relevant standards. When connecting the boiler to the gas supply pipe, only use appropriate washers and gas fittings. The use of hemp, PTFE tape and similar materials is not allowed. In areas prone to Copper Sulphide build-up in gas supply pipes (such as in Northern Ireland) an in-line filter should be fitted 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. TR05A153.B1107 22 INSTALLATION INSTRUCTIONS 4.7 Electrical connections 4.7.1 General warnings The connection to the mains power supply must be carried out by professionally qualified personnel, registered in accordance with current legislation. Always check to make sure that the appliance has an effective earth system. This requirement is only satisfied if it has been properly connected to an effective earth system installed in accordance with the requirements of current safety standards. This basic safety measure must be connected, checked and verified by professionally qualified personnel. In case of doubt, have the electrical system checked by a qualified electrician. The manufacturer will not be held liable for any damage or injury caused as a result of an ineffective earth system. ■ The boiler is designed to operate with a 230 V, 50 Hz supply. The connection to the mains electricity supply must be via a fused spur and the appliance must be protected by a 3A fuse. Make sure that the positions of the live and neutral wires correspond to the wiring diagram (Figure 15); ■ Ensure the domestic power supply is checked by a qualified electrician to ensure that it can support the maximum power absorption of the appliance, as indicated on the rating plate. In particular, make sure that the cable sizes are adequate for the power absorbed by the appliance; When using an electrical appliance, a few fundamental rules must be observed: • Do not touch the appliance with damp or wet parts of the body or when barefoot; • Do not pull on the electric wires; • Do not leave the appliance exposed to atmospheric elements (rain, sun, etc,) unless these conditions have been expressly provided for; • Do not allow the appliance to be used by children or anyone unfamiliar with its operation. TR05A153.B1107 23 INSTALLATION INSTRUCTIONS 4.7.2 Power supply The connection to the mains power supply must be carried out by professionally qualified personnel, registered in accordance with current legislation. Connect the power supply to the terminal board inside the control panel as follows: a. b. c. d. Ensure the supply is isolated; Remove the front casing panel of the boiler (refer to Section 6.3 for guidance); Remove terminal block cover A (see Figure 15); Connect the wires to terminal block B as follows (see Figure 15); • Connect the earth wire (coloured green/yellow) to the terminal marked with the earth symbol “ • Connect the neutral wire (coloured blue) to the terminal marked with the letter “ N ”; “; • Connect the permanent live wire (coloured brown) to the terminal marked with the letter “ L ”; e. Replace terminal block cover A. The appliance MUST be supplied with a permanent live in order for the boiler’s protective functions to operate correctly. These functions include frost protection, post-ventilation, pump overrun and pump & 3-way valve inactivity protection. On first connection to the power supply, the appliance must be switched on using the ON/OFF button on the control panel to activate all of the above protective features. The appliance can then be switched off but the protective features will remain active. Ta Ta Se Se The terminals marked Ta and Se are for external zero-voltage controls including room thermostats, time clocks, zoned system controls and weather compensating controls. Connection of these controls is covered in Section 0. TIME OFF N ON blue green/yellow L ON / OFF Figure 15: Power supply connections TR05A153.B1107 A B 24 brown INSTALLATION INSTRUCTIONS 4.8 Flue connections In order to ensure that the appliance functions correctly and efficiently, only Warmflow-approved flue components may be used with this appliance. Traditional flue components cannot be used for conveying exhaust fumes from condensing boilers. Coaxial Balanced Flues 0 N O 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. 0 N O 0 4 0 4 .5 0 5 . 0 5 0 6 0 7 8 0 O N 4 0 5 0 6 0 7 0 8 0 .5 0 5 0 6 7 0 8 0 C33 C32 C53 C52 C13 C12 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; .0 5 O N 4 0 5 0 6 0 7 0 0 8 0 5 . N O C43 C42 0 4 5 0 6 0 7 0 8 0 C83 C82 For the air intake duct of a twin pipe system, the entire length of Figure 16: Appliance and flue types the duct must slope downwards towards the exterior to prevent the entry of rainwater, dust or foreign bodies. Reference Information – Type C Appliances Exhaust flues for gas-fired appliances are classified at European level according to the method used for drawing combustion air to and discharging exhaust fumes from the appliance. This classification applies to gas-fired appliances in general. The combustion circuit (air intake, combustion chamber, heat exchanger and fumes exhaust discharge) of Type C Appliances is sealed off from the room in which the appliance is installed, i.e. room sealed. The combustion air intake and the fumes exhaust discharge are connected directly to the outside. TR05A153.B1107 25 INSTALLATION INSTRUCTIONS 4.8.1 Flue position The flue system MUST be installed in accordance with the recommendation contained in BS 5440:1. The boiler MUST be installed so that the terminal is exposed to the external air. It is important that the position of the terminal allows free passage of air across it at all times. If the terminal discharges into a pathway or passageway check that combustion products will not cause nuisance and that the terminal will not obstruct the passageway. In certain weather conditions a terminal may emit a plume of steam. Positions where this would cause a nuisance should be avoided. It is ESSENTIAL TO ENSURE, in practice, that products of combustion discharging from the terminal cannot re-enter the building, or any other adjacent building, through ventilators, windows, doors, other sources of natural air infiltration, or forced ventilation/air conditioning systems. If this should occur, the appliance MUST BE TURNED OFF IMMEDIATELY. Where the lowest part of the terminal is fitted less than 2m (6.6ft) above a balcony, above ground, or above a flat roof to which people have access, the terminal MUST be protected by a purpose designed guard. 300 min TERMINAL ASSEMBLY PROPERTY BOUNDARY LINE L TOP VIEW REAR FLUE K B.C G N D G J M D A E A F H,I F G Figure 17: Flue terminal positions – BS5440:1 A B C D E F G H I J K L M N Directly below an opening window, air vent or any other ventilation opening Below gutter, drain pipes or soil pipes Below eaves Below balcony or carport roof From vertical drain pipes or soil pipes From internal or external corners Above adjacent ground, roof or balcony level From a surface or boundary facing the terminal From a terminal facing the terminal From opening (door, window) in the carport into dwelling Vertically from a terminal on the same wall Horizontally from a terminal on the same wall Above an opening, air brick, opening window etc Horizontally to an opening, air brick, opening window, etc. TR05A153.B1107 26 300 75 200 200 150 300 300 600 1200 1200 1500 300 300 300 mm mm mm mm mm mm mm mm mm mm mm mm mm mm INSTALLATION INSTRUCTIONS 4.8.2 Horizontal coaxial balanced flue – Ø 60/100 (Kit K) FOR CONDENSING BOILERS ONLY Ø60/100 MAXIMUM FLUE LENGTH = 4 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 60/100 x 90° bend = 0.8 m Ø 60/100 x 45° bend = 0.5 m * If a flue length of above 4 metres is required, use the Ø 80/125 system. 450 100 60 100 60 Figure 18: Ø 60/100 Horizontal Kit K 107 830 946 160 HR 64.5 G 148 HF 182 130 55.5 330 Figure 19: Ø 60/100 Horizontal Kit K dimensions TR05A153.B1107 27 INSTALLATION INSTRUCTIONS 4.8.3 Horizontal coaxial balanced flue – Ø 80/125 FOR CONDENSING BOILERS ONLY Ø80/125 MAXIMUM FLUE LENGTH = 5 m * The flue length is the total length of the flue excluding the first bend. The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below). Ø 60/100 x 90° bend = 0.8 m Ø 60/100 x 45° bend = 0.5 m * If a flue length of above 5 metres is required, use the Twin Pipe system. 107 116 160 35 152 80 125 Figure 20: Ø 80/125 Horizontal Kit 82 830 286 762 82 HR HWO G 65.5 78 70 CWI 80 HF 102 55.5 130 330 450 Figure 21: Ø 80/125 Horizontal Kit dimensions TR05A153.B1107 28 INSTALLATION INSTRUCTIONS 4.8.4 Vertical coaxial balanced flue – Ø 60/100 (Kit V) FOR CONDENSING BOILERS ONLY Ø60/100 MAXIMUM FLUE LENGTH = 4 m * The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below). Ø 60/100 x 90° bend = 0.8 m Ø680/100 x 45° bend = 0.5 m * If a flue length of above 4 metres is required, use the Ø 80/125 system. max. 45.00 mt. Figure 22: Ø 60/100 Vertical Kit V Ø60 Ø100 107 = Ø60 Ø100 = 830 160 450 330 Figure 23: Ø 60/100 Vertical Kit V dimensions TR05A153.B1107 29 INSTALLATION INSTRUCTIONS 4.8.5 Vertical coaxial balanced flue – Ø 80/125 FOR CONDENSING BOILERS ONLY Ø80/125 MAXIMUM FLUE LENGTH = 5 m * The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below). Ø 60/100 x 90° bend = 0.8 m Ø680/100 x 45° bend = 0.5 m * If a flue length of above 5 metres is required, use the Twin Pipe system. max. 5.00 mt. Figure 24: Ø 80/125 Vertical Kit Ø80 Ø125 = Ø80 Ø125 = 160 830 107 450 330 Figure 25: Ø 80/125 Vertical Kit dimensions TR05A153.B1107 30 INSTALLATION INSTRUCTIONS 4.8.6 Flue diaphragm installation – Coaxial balanced flues The adjustable flue diaphragms MUST ONLY be installed on the top of the boiler. They MUST NOT be installed elsewhere in the flue system. Installation Instructions (see Figure 26): − Clean the surface of the boiler flue spigot; − Mount the neoprene gasket, lining up the holes with those on the flue spigot; − Place the lower diaphragm (with the numbered scale) onto the gasket; − Place the upper diaphragm (with the pointer) onto the lower diaphragm; − Assemble the flue starter piece by clamping the flange to the elbow using the screw and nut provided with the flue kit. Push the flared end of the Ø60 aluminium collar over the plastic inner pipe of the flue starter elbow ensuring a snug fit; − Mount the flue starter assembly onto the boiler, passing the screws (provided with the flue kit) through the flange, the top and bottom diaphragms and the gasket, then screwing them into the flue spigot; − Establish the total flue system length then adjust the flue diaphragms following the guidelines in Section 4.8.7; − ONLY WHEN THE DIAPHRAGMS HAVE BEEN ADJUSTED, tighten the screws to secure the diaphragms. Before switching on the appliance, DOUBLE CHECK that the screws have been tightened! 90° FLUE BEND Ø100/60 FIXING SCREW ALUMINIUM COLLAR Ø60 UPPER DISK FOR ADJUSTMENT LOWER DISK FOR ADJUSTMENT NEOPRENE SEALING GASKET Figure 26: Balanced flue diaphragm installation TR05A153.B1107 31 INSTALLATION INSTRUCTIONS 4.8.7 Flue diaphragm adjustment – Ø 60/100 Coaxial balanced flues NUMBERS FOR ADJUSTMENT INDICATOR 1 2 3 4 5 TOTAL EQUIVALENT FLUE LENGTH from 0 to 1 m DIAPHRAGM SETTING 1 2 3 4 5 Remove tags from both discs from 1 to 4 m Do not fit either disc MAXIMUM FLUE LENGTH 4m UPPER DISC COAXIAL BALANCED FLUES Ø 60/100 Horizontal (Kit K) and Vertical (Kit V) LOWER DISC Figure 27: Ø 60/100 Balanced flue diaphragm settings 4.8.8 Flue diaphragm adjustment – Ø 80/125 Coaxial balanced flues NUMBERS FOR ADJUSTMENT INDICATOR 1 2 3 4 5 TOTAL EQUIVALENT FLUE LENGTH from 0.5 to 1 m 1 2 3 4 5 from 1 to 2 m 1 2 3 4 5 1 2 3 4 5 from 2 to 3 m UPPER DISC LOWER DISC DIAPHRAGM SETTING from 3 to 4 m Remove tags from both discs 1 2 3 5 from 4 to 5 m Do not fit either disc MAXIMUM FLUE LENGTH 5m COAXIAL BALANCED FLUES Ø 80/125 Horizontal and Vertical Options Figure 28: Ø 80/125 Balanced flue diaphragm settings TR05A153.B1107 4 Remove tags from both discs 32 INSTALLATION INSTRUCTIONS 4.8.9 Twin Pipe flue system – Ø 80/80 (Kit H) FOR CONDENSING BOILERS ONLY Ø80/80 MAXIMUM FLUE LENGTH = 40 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 29: Ø 80/80 Twin Pipe Kit H 80 80 80 450 225 160 107 HR HWO G 64.5 78 70 CWI 80 HF 130 330 102 55.5 Figure 30: Ø 80/80 Twin Pipe Kit H dimensions TR05A153.B1107 830 970 224 33 INSTALLATION INSTRUCTIONS 4.8.10 Flue diaphragm installation – Twin pipe flues The adjustable flue diaphragms MUST ONLY be installed on the top of the boiler. They MUST NOT be installed elsewhere in the flue system. The adjustable flue diaphragms of a twin pipe system MUST be installed on the AIR INTAKE. Installation Instructions (see Figure 31): − Remove the air intake cover; − Clean the top surface of the boiler and of the boiler flue spigot; − Mount the two neoprene gaskets, lining up the holes with those on the flue spigot and around the air intake; − Push the flared end of the Ø60mm aluminium collar onto the plastic inner pipe of the flue exhaust starter piece, then fit the starter piece to the boiler passing the screws (provided with the flue kit) through the flange and gasket then screwing them into the flue spigot; − Place the lower diaphragm (with the numbered scale) onto the air intake gasket; − Place the upper diaphragm (with the pointer) onto the lower diaphragm; − Fit the air intake starter piece onto the boiler, passing the screws (provided with the flue kit) through the flange, the top and bottom diaphragms and the gasket then screwing them into the top of the boiler; − Establish the total flue system length then adjust the flue diaphragms following the guidelines in Section 4.8.11; − ONLY WHEN THE DIAPHRAGMS HAVE BEEN ADJUSTED, tighten the screws to secure the diaphragms. Before firing, DOUBLE CHECK that the screws have been tightened! Ø80 VERTICAL CONNECTION EXHAUST ALUMINIUM COLLAR Ø 60 NEOPRENE SEALING GASKET Figure 31: Twin pipe flue diaphragm installation TR05A153.B1107 34 INSTALLATION INSTRUCTIONS 4.8.11 Flue diaphragm adjustment – Ø 80/80 Twin pipe flues 1 2 3 NUMBERS FOR ADJUSTMENT INDICATOR TOTAL EQUIVALENT FLUE LENGTH from 0 to 10 m including inlet & exhaust sections from 10 to 30 m including inlet & exhaust sections from 30 to 40 m UPPER DISK including inlet & exhaust sections DIAPHRAGM SETTING 1 2 3 1 2 3 Do not fit either disc MAXIMUM FLUE LENGTH TWIN PIPE FLUES Ø 80/80 Kit H LOWER DISK Figure 32: Ø 80/80 Twin pipe flue diaphragm settings TR05A153.B1107 35 40 m COMMISSIONING INSTRUCTIONS 5 COMMISSIONING 5.1 General warnings The following operations must be carried out by professionally qualified personnel, registered in accordance with current legislation. Reference should be made to BS 5449:5 - Commissioning. The boiler leaves the factory pre-set and tested for burning Natural Gas (Methane). Nevertheless, when starting the boiler for the first time, make sure that the information on the rating plate corresponds to the type of gas being supplied to the boiler. Once the system has been filled and the necessary adjustments made, remember to tighten the screws of the gas valve test point and make sure that there are no gas leaks from the test point and from any pipe fittings upstream of the gas valve. ■ Preliminary operations Switching the boiler on for the first time means checking that the installation, regulation and operation of the appliance are correct. The commissioning engineer MUST check, referring to the previous sections of this manual, the following:• That the data on the data plate corresponds to that of the mains supply networks (gas, electricity, water); • That the power supply voltage to the boiler complies with the data plate (230 V – 50 Hz) and that the live, neutral and earth wires are correctly connected. Also, that the earth connection is sound and that the appliance is effectively earthed; • That the gas supply is correctly sized for the flow rate required by the boiler and that it is fitted with all the safety and control devices as lay down by current regulations; • That all mechanical connections are sound and have not become loose during transportation and handling; • That the seals on the gas supply pipe from the mains are sound, and that the meter does not register any flow of gas; • That the flue system (air intake and exhaust ducts) is installed correctly and in line with current law and national and local standards; • The all permanent combustion air and ventilation openings as required by current law for the type of appliances installed are provided and are not blocked; • That the condensate drainage system(s) are installed correctly and in line with current law and national and local standards; • That the condensate drainage system, including outside the boiler (condensate collection devices), allows the condensate to flow freely to the drain. Check that no exhaust fumes could discharge into the drainage system; • That there are no flammable materials or liquids in the immediate vicinity of the boiler. The commissioning engineer must then:• Flush out both the central heating and domestic hot water circuits (see Section 5.3); • Turn the gas supply on and purge according to BS6891. • Test for gas soundness (let-by and tightness tests). TR05A153.B1107 36 COMMISSIONING INSTRUCTIONS 5.2 Filling the system Use only a WRAS approved filling loop for connection and filling of the primary system. This should be disconnected when not in use (see Section 4.4.3). AIR VENT VALVE AIR VENT VALVE PLUG PUMP Check the properties of the water supply and install the appropriate treatment devices if the mains water has a hardness rating more than 17.5 °Ck in order to prevent scaling and eventual damage to the DHW heat exchanger. 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: Figure 33: Air vent and pump bleed plugs • Slacken the air vent valve plug to allow air to escape from the system (see Figure 33); • 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; • 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 34) to monitor the system pressure. Close the external filling loop when the system pressure reaches 1 bar and check that Error Code H2O Figure 34: Pressure gauge and boiler drain is NOT displayed on the control panel display (see Section 3.6); RS M • 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. 5.3 Flushing the system Failure to flush and add inhibitor to the system will invalidate the warranty. The system must be thoroughly drained and flushed out using flushing agents/descalers that comply with BS7593. When refilling the system, appropriate corrosion inhibitors and softening agents must be added. a. Fill the boiler as per the filling instructions; b. Use a drain cock on the lowest point of the system to allow the water to drain from both the system and boiler; c. To flush the system correctly, turn off all radiators, open the filling loop and drain cock simultaneously and allow the water to flow through the boiler; d. For each radiator on the system in turn, open the radiator valves, allowing water to flow through, then turn that radiator off. Repeat for all the radiators on the system; e. Close the drain cock, re-open all radiators and fill the system following the instructions in Section 5.2; f. Continue to fill the system until the pressure gauge reaches 1 bar. TR05A153.B1107 37 COMMISSIONING INSTRUCTIONS 5.4 Filling the condensate trap The condensation trap MUST be pre-filled when starting the boiler for the first time in order to prevent flue gases from escaping via the drain. The filling operation is carried out as follows (see Figure 35): • Remove plug T and fill the trap S three quarters full with water; • Replace plug T and connect the drainpipe P. The trap should be cleaned after a few months of boiler operation, as deposits/residues drawn out of the heat exchanger may impair the operation of the trap. T Figure 35: Condensate trap 5.5 Starting 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 valves are open (CH and DHW circuits and gas); • Switch on the power supply to the boiler; • Switch the boiler on using the ON/OFF button on the Control Panel (see Section 3.6). After a few seconds the circulating pump will start to run; • Ensure that the boiler controls, time clock and any 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 again 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 Section 5.2). If the pressure has fallen, re-open the filling loop until the pressure gauge reads 1 bar. Check that Error Code H2O is NOT displayed on the Control Panel display. On completion, close the filling loop; • Check the gas pressures as described in Section 5.6. TR05A153.B1107 38 COMMISSIONING INSTRUCTIONS 5.6 Checking gas pressures 5.6.1 Working pressure (at meter and appliance) The working pressure at the meter should be checked to confirm that it corresponds to the value stated on the meter regulator. The appliance inlet working pressure should be checked to confirm that it corresponds to the value stated on the boiler data plate and in Section 5.8, and also that there is no excessive pressure loss in the supply pipe work. To operate the appliance at maximum gas rate: Once the boiler has been successfully fired (to eliminate all air from the gas supply line): • Access the Control Parameters Menu following the instructions in Section 5.7.1; • Adjust the value of Parameter 11 to 99 following the instructions in Section 5.7.2; • Switch the appliance on then press and hold the S button for 7 seconds to activate Commissioning Mode. You can exit Commissioning Mode at any time by turning the appliance off using the ON/OFF button. The boiler will ignite and operate at maximum gas rate for 15 minutes (or until the CH system reaches maximum temperature). A gas rate should be performed whilst operating the appliance as described above. To measure the working pressure at the meter: • Switch the appliance off (see Section 3.6) and close the meter isolation valve; • Connect a pressure gauge to the meter outlet sampling point; • Reopen the meter isolation valve and operate the appliance at maximum gas rate as described above. The pressure gauge will now measure the working pressure at the meter. Check that the pressure measured on the gauge is equal to the value stated on the meter installation. When the pressure has been checked: • Switch off the appliance and close the meter isolation valve; • Disconnect the pressure gauge then reopen the meter isolation valve. If the measured pressure does not equal that stated on the installation and you are connected to a mains natural gas supply: • Contact your gas supplier to report the problem. If the measured pressure does not equal that stated on the installation and you are using LPG: A B • Adjust the supply pressure using the supply regulator. To measure the working pressure at the appliance: 40 C • Switch the appliance off (see Section 3.6); 30 40 • Close the appliance gas supply isolation valve; D • Connect a pressure gauge to pressure point C of the gas valve (see Figure 36); • Open the appliance gas supply isolation valve and operate the appliance at maximum gas rate as described above. The pressure gauge will now measure the appliance inlet working pressure. Check that the pressure measured on the gauge is equal to the supply inlet gas pressure stated on the boiler data plate and that it is not more than 1 mbar less than the working pressure at the meter. 20 30 10 20 10 MANOMETRO Fig. 1 Figure 36: Supply inlet gas pressure measurement TR05A153.B1107 39 COMMISSIONING INSTRUCTIONS When the pressure has been checked: • Switch off the appliance and close the gas supply isolation valve; • Disconnect the pressure gauge then reopen the isolation valve. If the measured pressure does not equal that stated on data plate, or if it is more than 1 mbar less than the working pressure at the meter, check the gas supply pipe work. Confirm that the pipe work is correctly sized and that there is no blockage. 5.6.2 Mechanical minimum gas pressure The minimum gas pressure for this appliance has been factory set. Nonetheless, it must be checked to confirm that it corresponds to the value stated on the boiler data plate and in Section 5.8. A Once the boiler has been successfully fired (to eliminate all air from the gas supply line): B • Switch the appliance on, select Heating Only Mode, then switch the appliance off (see Section 3.6); 40 C 30 • Connect a pressure gauge to pressure point B of the gas valve (see Figure 37); D 20 • Switch the appliance on. The boiler will operate at the minimum gas pressure for 10 seconds prior to the burner ignition sequence. Check that the pressure measured on the gauge is equal to the minimum gas pressure stated on the boiler data plate. 10 MANOMETRO If the measured pressure does not equal that stated on the data plate: • Adjust the minimum gas pressure by turning screw D on the gas valve using a screw driver; Fig. 1 • Switch the appliance off before disconnecting the pressure gauge. Figure 37: Burner gas pressure adjustment 5.6.3 Mechanical maximum gas pressure The maximum gas pressure for this appliance has been factory set. Nonetheless, it must be checked to confirm that it corresponds to the value stated on the boiler data plate and in Section 5.8. Once the boiler has been successfully fired (to eliminate all air from the gas supply line): • Switch the appliance off (see Section 3.6); • Connect a pressure gauge to pressure point B of the gas valve (see Figure 37); • Operate the appliance at maximum gas rate as described in Section 5.6.1; Check that the maximum gas pressure is equal to the value stated on the boiler data plate. If the measured pressure does not equal that stated on the data plate: • Remove plug A on the gas valve and adjust the maximum gas pressure by turning the screw underneath the plug using a screw driver; • Switch the appliance off before disconnecting the pressure gauge. 5.6.4 Maximum and minimum CH gas pressures The minimum CH gas pressure for this appliance has been factory set and should not need to be adjusted. However, it can be adjusted using Control Parameter 10 (see Section 5.6). In order to maximise appliance efficiency and minimise noise, it is essential to match the appliance maximum CH output to the heating demand of the system. This is achieved by limiting the maximum CH gas pressure using Control Parameter 11 (see Section 5.6) and following the instruction below. TR05A153.B1107 40 COMMISSIONING INSTRUCTIONS Once the boiler has been successfully fired (to eliminate all air from the gas supply line): • Access the Control Parameters Menu following the instructions in Section 5.7.1; • Access Parameter 11, following the instructions in Section 5.7.2, at which point the boiler will fire; • Referring to the Heating Output vs. Parameter Value curves in Figure 38, adjust the value of Parameter 11 to the desired output; • Complete the Parameter adjustment process following the instructions in Section 5.7.2; 5.6.5 Ignition sequence gas pressures The ignition sequence gas pressure for this appliance has been factory set and should not need to be adjusted. However, it can be adjusted using Control Parameter 12 (see Section 5.6). TR05A153.B1107 41 COMMISSIONING INSTRUCTIONS 5.7 Control parameters PARAMETER NUMBER PARAMETER NAME PARAMETER VALUE FUNCTION 1 Boiler type 00 01 02 00 01 Non-storage boiler Storage boiler (type 1) Storage boiler (type 2) Natural gas LPG 2 Fuel type 3 CH flow temperature 00 01 Standard (30-80°C) for radiators Reduced (25-40°C) for under floor 4 CH pump mode 00 01 Runs when controls call for heat. Runs continuously when appliance is on. 5 Water Hammer prevention (Delays operation of DHW flow switch) 00 01 Off On (2 second delay) 6 Short cycling prevention (CH delay timer) 00-90 (default = 36) Expressed in steps of 5 seconds (Default = 36 x 5 sec = 180 sec) 7 CH pump overrun timer 00-90 (default = 36) Expressed in steps of 5 seconds (Default = 36 x 5 sec = 180 sec) 8 DHW pump overrun timer 00-90 (default = 18) Expressed in steps of 5 seconds (Default = 18 x 5 sec = 90 sec) 9 Minimum gas pressure 00-50 (default = 20) Expressed in % of gas valve range (Default = 20% open) 10 Minimum gas pressure (in CH mode) 00-50 (default = 20) Expressed in % of gas valve range (Default = 20% open) 11 Maximum gas pressure (in CH mode) 00-99 (default = 99) Expressed in % of gas valve range (Default = 99% open) 12 Ignition sequence gas pressure 00-99 (default = 50) Expressed in % of gas valve range (Default = 50% open) 13 Priority DHW (Delays switching back to CH mode) 00 01 Off On (2 minute delay) 14 - - Not applicable to this appliance 15 - - Not applicable to this appliance 16 - - Not applicable to this appliance 17 - - Not applicable to this appliance 18 - - Not applicable to this appliance 19 - - Not applicable to this appliance 20 - - Not applicable to this appliance 21 - - Not applicable to this appliance 22 - - Not applicable to this appliance Table 5: Control Parameters NOTES Factory default values highlighted in bold. Parameters 1 highlighted in grey only needs to be adjusted when replacing the PCB. TR05A153.B1107 42 COMMISSIONING INSTRUCTIONS 5.7.1 Accessing the parameters menu Step 1: Switch the appliance off using the ON/OFF button. OFF S Step 2: Press and hold both the & buttons. Switch the appliance on using the ON/OFF button. Release the & buttons. PL S Step 3: Press and hold the S button. Use the button to cycle up through the parameters. 0 S 1 S TR05A153.B1107 Step 4: Release the S button. Press and release the S button again. The value of the selected parameter will be displayed. Follow the instructions in the following section (Section 5.7.2) to adjust parameter values. 43 COMMISSIONING INSTRUCTIONS 5.7.2 Adjusting the parameters 00 S 1 Parameter 1 – Boiler type Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Non-storage boiler; 01 = Storage boiler (type 1); 02 = Storage boiler (type 2). Press and release the S 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. S 01 00 S 2 Parameter 2 – Fuel type Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Natural gas (Methane) 01 = LPG Press and release the S 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. S 00 S 3 Parameter 3 – CH flow temperature Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Standard (30 – 80°C) for radiators 01 = Reduced (25 – 40°C) for under-floor heating Press and release the S 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. S TR05A153.B1107 44 COMMISSIONING INSTRUCTIONS 00 00 S 1 4 Parameter 4 – CH pump mode Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Runs when controls call for heat 01 = Runs continuously when appliance is on Press and release the S 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. S 01 00 S 52 Parameter 5 – Water Hammer prevention Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Off 01 = On Press and release the S 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. S 00 36 S 3 6 Parameter 6 – Short-cycling prevention (CH delay timer) Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = 0 x 5 seconds = 0 seconds (minimum) 90 = 90 x 5 seconds = 450 seconds (maximum) Note: Factory preset to 36 = 180 seconds Press and release the S 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. S TR05A153.B1107 45 COMMISSIONING INSTRUCTIONS 36 S 7 Parameter 7 – CH pump overrun timer Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = 0 x 5 seconds = 0 seconds (minimum) 90 = 90 x 5 seconds = 450 seconds (maximum) Note: Factory preset to 36 = 180 seconds Press and release the S 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. S 18 S 8 Parameter 8 – DHW pump overrun timer Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = 0 x 5 seconds = 0 seconds (minimum) 90 = 90 x 5 seconds = 450 seconds (maximum) Note: Factory preset to 18 = 90 seconds Press and release the S 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. S 120 8 S 9 S TR05A153.B1107 Parameter 9 – Minimum gas pressure Refer to Section 5.6. Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Gas valve at mechanical minimum gas pressure 50 = Gas valve 50% open (maximum) Note: Factory preset to 20 = Gas valve 20% open Press and release the S button. The parameter number (9) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button. 46 COMMISSIONING INSTRUCTIONS 24 50 S 10 S 66 99 S 11 S 66 50 S 11 12 S 01 S 13 Parameter 10 – Minimum gas pressure (in CH mode) Refer to Section 5.6. Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Gas valve at mechanical minimum gas pressure 50 = Gas valve 50% open (maximum) Note: Factory preset to 20 = Gas valve 20% open Press and release the S button. The parameter number (10) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button. Parameter 11 – Maximum gas pressure (in CH mode) Refer to Section 5.6. Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Gas valve at mechanical minimum gas pressure 99 = Gas valve at mechanical maximum gas pressure Note: Factory preset to 99 = Gas valve at max. pressure Press and release the S button. The parameter number (11) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button. Parameter 12 – Ignition sequence gas pressure Refer to Section 5.6. Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Gas valve at mechanical minimum gas pressure 99 = Gas valve at mechanical maximum gas pressure Note: Factory preset to 50 = Gas valve 50% open Press and release the S button. The parameter number (12) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button. Parameter 13 – Priority DHW Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Off 01 = On (2 minute delay) Press and release the S 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. S Parameters 14 through 22 Not applicable to this appliance TR05A153.B1107 47 COMMISSIONING INSTRUCTIONS 5.8 Gas data 5.8.1 Technical reference tables Gas Type Minimum Gas Pressure / mbar Maximum Gas Pressure / mbar 3.1 7.5 10.9 9.0 26.6 32.4 Natural Gas (Methane) – G20 LPG (Butane) – G30 LPG (Propane) – G31 Table 6: Reference fan speeds Lower Wobbe index (15ºC; 1013 mbar) Natural Gas G20 Liquid Butane Gas G30 Liquid Propane Gas G31 45.67 80.58 70.69 mbar 20 30 37 3 m /h 3.17 - - kg/h - 2.37 2.33 MJ/Nm Nominal Supply Pressure Consumption (15ºC; 1013 mbar) Consumption (15ºC; 1013 mbar) 3 Table 7: Reference gas data 32 30 28 26 24 Heating power in kW 22 20 18 G 20 16 G 30 G 31 14 12 10 8 6 4 2 0 0 5 10 15 20 25 G 20 - Natural gas G 30 - Butane G 31 - Propane 30 35 40 45 55 Parameter value Figure 38: Heating Output vs Parameter Value TR05A153.B1107 50 48 60 65 70 75 80 85 90 95 100 COMMISSIONING INSTRUCTIONS 5.9 Converting to a different gas type 9 7 7 6 6 8 10 11 5 8 5 2 4 3 1 Figure 39: Gas type convertion The conversion of a boiler from burning natural gas to LPG, or vice versa, must only be carried out by professionally qualified personnel registered in accordance with current legislation. Before carrying out a conversion, ensure that the gas supply pipe is suitable for the new fuel type. Conversion of this appliance is performed as follows: a. Isolate the electricity, water and gas supplies to the appliance; b. Substitute the jets on the main burner as follows: • Undo the gas pipe (item 5 of Figure 39) from the burner manifold using a 24mm spanner; LEGEND: 1. GAS VALVE 2. STABILISER 3. INLET PRESSURE POINT 4. OUTLET PRESSURE POINT 5. GAS PIPE 6. BURNER MANIFOLD 7. RAMP GAS BURNER 8. INJECTORS 9. IGNITION ELECTRODES 10. FLAME IONISATION ELECTRODES 11. MANIFOLD SECURING SCREW • Separate the burner manifold (item 6) from the burner ramps (item 7) by undoing the 4 screws (item 11); • Fit new jets (item 8) (suitable for the new gas type) to the burner using a 7mm spanner and fitting with new gaskets; • Reassemble the entire burner unit. • Turn on the gas supply and check for leaks using soapy water or leak detector spray; d. Program the new control parameters (maximum & minimum gas pressures) (see Sections 5.6); e. Replace the appliance gas data plate so as to indicate the new gas type and gas data for the boiler. A new label will be provided in the conversion fittings kit. TR05A153.B1107 49 MAINTENANCE INSTRUCTIONS 6 MAINTENANCE 6.1 General warnings All maintenance operations must be carried out by professionally qualified personnel. The frequency of boiler maintenance must comply with current law and should, in any case, be carried out annually. In order to guarantee the long life of the appliance, and in accordance with the current gas safety regulations, only use original spare parts. Before carrying out any type of maintenance operation, disconnect the appliance from the mains electricity supply and close the gas valve. 6.2 Boiler inspection In order to ensure that the boiler operates efficiently and safely, it is recommended that the appliance is inspected by a suitably competent technician at least once a year. The following must be checked annually: ■ The condition of the gas seals – replace where necessary; ■ The condition of the water seals – replace where necessary; ■ The condition of the combustion chamber and flame; ■ The combustion parameters – if necessary adjust in line with Sections 5.6; ■ 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 gas pressures and the modulation process – adjust if necessary; ■ The condition and operation of the ignition and gas safety systems – if necessary remove and clean any scaling from the ignition and flame detection electrodes, paying particular attention to replace them at the correct distance from the burner (see Section 6.7.3); ■ The heating safety systems: temperature and pressure limit devices – replace where necessary; ■ The expansion vessel pre-charge pressure (should be 1 bar when cold) – if necessary refer to Section 4.4.3; ■ The integrity and operation of the flue system – correct where necessary; ■ That the mains electricity supply is safe and correctly rated (refer to Section 4.7) – correct where necessary; ■ The electrical connections inside the control panel – correct where necessary; ■ The DHW flow rate and temperature (refer to Section 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. TR05A153.B1107 50 MAINTENANCE INSTRUCTIONS 6.3 Accessing the boiler All maintenance operations require one or more of the boiler casing panels to be removed. 6.3.1 Front panel removal • Remove the fixing screws at the lower edge of the front panel; • Grasp the lower part of the panel and pull it outwards and then upwards (see Figure 40). 6.3.2 Side panel removal • The side panels can only be removed after the front panel has been removed; • Remove the fixing screws at the front and lower edge of the side panel; • Grasp the bottom of the panel, move it sideways and then upwards (see Figure 40). Figure 40: Front and side panel removal 6.3.3 Control panel access • Remove the front panel (refer to 6.3.1 above); • Grasp the left and right control panel support brackets and pull them outwards, at the same time rotating the panel downwards (see Figure 41); • Unscrew the four cover securing screws and remove the control panel rear cover. Figure 41: Control panel access TR05A153.B1107 51 MAINTENANCE INSTRUCTIONS 6.4 Draining the central heating system If the ENTIRE SYSTEM needs to be drained: • Switch on the boiler, select Heating Only Mode and allow the boiler to fire. Refer to 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 42); • Open the air vents on the radiators, starting with the highest and moving down the system to the lowest; • When the system has been Figure 42: Boiler drain valve drained, close the radiator air vents and the boiler drain valve. If ONLY THE BOILER needs to be drained: • Switch on the boiler, select Heating Only Mode and allow the boiler to fire. Refer to Section 3.6 for how to operate the appliance; • Isolate the electricity and gas supplies to the boiler and wait for the boiler to cool down; • Close the isolating valves on the heating circuit flow and return pipes; • Connect a hosepipe to the system drain point and locate the other end of the hose in a suitable drain; • Open the drain valve located at the bottom of the boiler on the pump manifold (see Figure 42); 6.5 Flushing the central heating system Refer to the detailed instructions in Section 5.3. 6.6 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. TR05A153.B1107 52 MAINTENANCE INSTRUCTIONS 6.7 Maintenance operations Before carrying out any cleaning or part replacement operations, ALWAYS turn off the ELECTRICITY, WATER and GAS supplies to the boiler. Warmflow will not be held responsible for damage to any of the boiler’s components caused by non-compliance with this instruction. Section 6.3 gives instructions on accessing the boiler, removing casing panels, and accessing the control panel. Expansion vessel Air pressure switch Secondary heat exchanger Electric fan Primary heat exchanger Safety thermostat Heating sensor Ignition electrode Ionisation electrode DHW sensor DHW heat exchanger Circulating pump Condensate trap 3-way diverter valve Gas valve Ignition transformer Figure 43: Key components TR05A153.B1107 53 MAINTENANCE INSTRUCTIONS 6.7.1 Primary heat exchanger and burner unit • Isolate the electricity, water and gas supplies to the appliance; • Remove the casing panels (see Section 6.3); • Remove the fixing screws of the combustion camber front panel and pull the panel outwards; • Unplug the ignition and ionisation electrode wires from the ignition control unit; • Check that the burner and heat exchanger surfaces are not affected by deposits, scaling or oxidation; • Clean the burner and heat exchanger surfaces using a non-metal brush and compressed air or an aspirator; • Check that all burner jets unobstructed and undamaged; are clean, • Clean the ignition and ionisation electrodes carefully and without altering their position with respect to the burner; • Check that the ignition electrode is positioned with a 3mm gap between it and the burner and that the ionisation electrode is not touching the burner surface; • Remove the condensate drain pipe and clean under running water; • Remove the condensate trap and clean under running water; Combustion chamber front panel Figure 44: Combustion chamber front panel Primary heat exchanger • 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. Burner Figure 45: Exchanger and burner TR05A153.B1107 54 MAINTENANCE INSTRUCTIONS 6.7.2 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 Sections 6.4 & 6.6); • Use a 4 mm Allen key to unscrew the two 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 Figure 46: DHW heat exchanger reverse order; • Refill the system (see Section 5.2) and check for any leaks from the joints. 6.7.3 Ignition and ionisation electrodes • Isolate the electricity, water and gas supplies to the appliance; • Unplug the electrode wires; Ionisation electrode • Slacken the fixing screws; • Remove the electrodes. When replacing, check that the seals are not damaged and renew if necessary; • Reconnect the wires and reassemble the components following the above procedure in reverse order; • Switch on the electricity, water and gas supplies and restart the appliance; If the boiler does not restart, check the positions of the electrodes. The ignition electrode should be positioned with a 3mm gap between it and the burner. The ionisation electrode must not be touching the burner surface. Ignition electrode Figure 47: Ignition and ionisation electrodes TR05A153.B1107 55 MAINTENANCE INSTRUCTIONS 6.7.4 Safety thermostat • Isolate the electricity, water supplies to the appliance; and gas Safety thermostat • Disconnect the connecting wire; • Unscrew the fixing screws and remove the thermostat; • Replace the thermostat and re-assemble the components following the above procedure in reverse order; 6.7.5 Heating sensor • Isolate the electricity, water supplies to the appliance; and gas • Unplug the connecting wires; • Replace the sensor and reconnect the wires; 6.7.6 Gas valve • Isolate the electricity, water supplies to the appliance; and gas • Disconnect and remove the pipe connecting the gas valve to the burner; • Disconnect the gas feed pipe; • Remove the screws securing the gas valve then remove the valve; • Replace the gas valve and reassemble the components following the above procedure in reverse order replacing all the gas seals; • Fully tighten the gas connections; • Switch on the gas supply and check for any gas leaks using a soapy solution or leak detector spray; Electronic gas valve • Switch on the electricity and water supplies, switch on and fire the appliance and repeat the checks for leaks. Gas isolation valve Figure 48: Heating sensors and gas valve TR05A153.B1107 56 Heating sensor MAINTENANCE INSTRUCTIONS 6.7.7 Electric fan • Isolate the electricity, water and gas supplies to the appliance; • Disconnect the fan electrical connections • Remove the fan bracket fixing screws; • Take hold of the fan body and shift it to the right, then pull it forwards and out of its mounting; • Replace the electric fan and reassemble the components following the above procedure in reverse order. • Switch on the electricity, water and gas supplies and check the soundness of the joint by measuring the CO2 levels; 6.7.8 Expansion vessel • Isolate the electricity, water and gas supplies to the appliance; Figure 49: Fan assembly Expansion vessel • Drain the central heating circuit of the boiler (see Section 6.4); • Unscrew the vessel pipe coupling; Vessel pipe • Push the expansion vessel securing tabs outwards to free the vessel; • Lift out the vessel whilst rotating it anticlockwise; • Replace the expansion vessel and reassemble the components following the above procedure in reverse order; • Switch on the electricity, water and gas supplies; • Refill the system (see Section 5.2) and check for any leaks. Vessel securing tab Figure 50: Expansion vessel removal TR05A153.B1107 57 MAINTENANCE INSTRUCTIONS 6.7.9 Circulating pump motor body • Isolate the electricity, water and gas supplies to the appliance; • Drain the central heating circuit of the boiler (see Section 6.4); Pump impeller body • Use a 5 mm Allen key to unscrew the four screws securing the motor body to the impeller body; Pump motor body • Remove the motor body and check the condition of the gasket. Replace if necessary; • Replace the pump motor body and reassemble the components following the above procedure in reverse order; • Switch on the electricity, water and gas supplies; • Refill the system (see Section 5.2) and check for any leaks. Figure 51: Circulating pump 6.7.10 3-way diverter valve Replacing the valve motor • Isolate the electricity, water and gas supplies to the appliance; Diverter valve body • Unscrew the fixing screws securing the transparent cover of the diverter valve and remove the cover; • Unscrew the two motor disconnect the wires; fixing screws and • 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 Section 6.4); Diverter valve motor • Unscrew the fixing screws securing the transparent cover of the diverter valve and remove the cover; • Unscrew the four fixing screws and remove the Figure 52: 3-way diverter valve diverter valve body and gasket; • Replace the valve body and reassemble the components following the above procedure in reverse order; • Switch on the electricity, water and gas supplies; • Refill the system (see Section 5.2) and check for any leaks. TR05A153.B1107 58 MAINTENANCE INSTRUCTIONS 6.7.11 Printed circuit board (PCB) • Isolate the electricity, water and gas supplies to the appliance; Printed circuit board (PCB) • Access the control panel (see Section 6.3); • Disconnect all the connectors, remove the control knobs from the front of the panel, unscrew the fixing screws and remove the PCB; • Replace the PCB and reassemble the components following the above procedure in reverse order; • Switch on the electricity, water and gas supplies; • Program the boiler control parameters following the instructions in Section 5.6. Printed circuit board (PCB) Figure 53: Printed circuit board (PCB) TR05A153.B1107 59 MAINTENANCE INSTRUCTIONS 6.7.12 Secondary heat exchanger • Isolate the electricity, water and gas supplies to the appliance; • Drain the central heating circuit of the boiler (see Section 6.4); • Remove the fixing spring clips and then the flow, return and condensate drain pipes; Support bracket screws Secondary heat exchanger • Remove the flue safety thermostat; • Unscrew the nuts and fixings screws of the secondary heat exchanger support bracket, then remove the bracket; • Remove the secondary heat exchanger by pulling it to the left, taking care not to snag the fan wiring; • Replace the heat exchanger and reassemble the components following the above procedure in reverse order; • Switch on the electricity, water and gas supplies; • Refill the system (see Section 5.2) and check for any water leaks; • Fire the boiler and check for any flue gas leaks. Flow, return and condensate drain pipes Support bracket Figure 54: Secondary heat exchanger removal TR05A153.B1107 60 MAINTENANCE INSTRUCTIONS 6.8 Internal wiring PRINTED CIRCUIT BOARD DIGITECH - SM20019 COD. 16766077 Key IG PA TS TF SR SS EV SE ER EA TRA VD C MF PACQ DHW CH ON/OFF button Air pressure switch Heating safety thermostat Flue safety thermostat Heating sensor DHW sensor Fan Outside sensor (optional) Ionisation electrode Ignition electrode Ignition transformer 3-way valve Circulating pump Micro flow switch Water pressure switch Domestic hot water Central heating black CVI-M VK 4105 G black POWER SUPPLY M7 blue brown red orange blue brown Telephone control blue brown Remote "Open therm" EXTERNAL CONTROLS M9 M10 61 remote controller zone valve blue black black brown Storage cylinder timer (option) orange black Zone valve management + option remote controller board Fine corsa valvole di zona contatto pulito M6 M2 Figure 55: Internal wiring diagram TR05A153.B1107 orange black red-black white-black blue M1 blue brown brown blue orange orange CH blue brown black blue brown DHW M5 M4 MAINTENANCE INSTRUCTIONS 6.9 Troubleshooting 6.9.1 Error codes CODE PROBLEM E01 NO FLAME (FLAME FAILURE DURING START-UP) POSSIBLE CAUSE REMEDY IF BOILER FAILS TO FIRE a. NO GAS b. GAS INLET PRESSURE TOO HIGH c. MECHANICAL MINIMUM OR IGNITION SEQUENCE GAS PRESSURES TOO LOW a. b. c. d. e. IGNITION ELECTRODE BROKEN OR EARTHED GAS VALVE MALFUNCTION d. e. CHECK MAINS SUPPLY CHECK INLET PRESSURE CHECK AND ADJUST MECHANICAL MINIMUM AND IGNITION SEQUENCE SETTINGS REPLACE PART REPLACE PART IF BOILER FIRES NORMALLY f. MAINS LIVE AND NEUTRAL WIRES REVERSED g. IONISATION ELECTRODE CABLE DISCONNECTED h. IONISATION ELECTRODE MALFUNCTION f. g. h. CORRECT MAINS WIRING CHECK ELECTRODE WIRING REPLACE PART E02 SAFETY THERMOSTAT TRIPPED (95°C) a. b. THERMOSTAT CABLE DISCONNECTED THERMOSTAT MALFUNCTION a. b. CHECK THERMOSTAT WIRING REPLACE PART E03 FLUE THERMOSTAT TRIPPED a. b. THERMOSTAT CABLE DISCONNECTED THERMOSTAT MALFUNCTION a. b. CHECK THERMOSTAT WIRING REPLACE PART H20 LOW SYSTEM PRESSURE a. b. c. INSUFFICIENT WATER PRESSURE IN THE SYSTEM WATER PRESSURE SWITCH CABLE DISCONNECTED WATER PRESSURE SWITCH MALFUNCTION a. b. c. TOP UP THE SYSTEM CHECK SWITCH WIRING REPLACE PART E05 HEATING SENSOR FAULT a. b. SENSOR CABLE DISCONNECTED OR WET SENSOR MALFUNCTION OR OUT OF CALIBRATION (RESISTANCE VALUE 10 kOhms AT 25 °C). a. b. CHECK SENSOR WIRING CHECK SENSOR RESISTANCE. REPLACE IF INCORRECT E06 DHW SENSOR FAULT a. b. SENSOR CABLE DISCONNECTED OR WET SENSOR MALFUNCTION OR INCORRECT (RESISTANCE VALUE 10 kOhms AT 25 °C). a. b. CHECK SENSOR WIRING CHECK SENSOR RESISTANCE. REPLACE IF INCORRECT E14 AIR PRESSURE SWITCH FAULT a. b. c. d. AIR PRESSURE SWITCH CABLE DISCONECTED FLUE INTAKE OR EXHAUST DUCT(S) BLOCKED FAN VENTURI BLOCKED OR DIRTY AIR PRESSURE SWITCH MALFUNCTION a. b. c. d. CHECK SWITCH WIRING UNBLOCK DUCT(S) CLEAN FAN VENTURI REPLACE PART E22 PARAMETER PROGRAMMING REQUEST a. LOSS OF MICROPROCESSOR MEMORY a. REPROGRAM PARAMETERS Table 8: Appliance error codes TR05A153.B1107 62 MAINTENANCE INSTRUCTIONS 6.10 Parts lists 6.10.1 Main components CODE DESCRIPTION 28200047 PLATE EXCHANGER 20 P. 10210032 BURNER 17 R. 1.20 NAT. GAS (Natural gas burner) 10210033 BURNER 17 R. 0.75 GPL (LPG burner) 12240045 PUMP RSL 15/5-3-KU-CLF6 w/OPEN C1+C3 46270044 CONDENSATE TRAP 10350007 IGNITION ELECTRODE E. 10350009 IONISATION ELECTRODE E. 50360074 ELECTRONIC GAS VALVE 1/4" 20370031 FAN 28432074 WASHER/OR CLIPS KIT FOR MULTIPLEX 40580025 HEAT EXCHANGER 32590012 AIR PRESSURE SWITCH 40580022 RECUPERATOR 28/32Kw. X155-Y188 28590015 WATER PRESSURE SWITCH PC 5411 OTTONE 28735007 DHW-HEATING SENSOR 1/8" WHITE 40735016 HTG CLIP SENSOR x PIPE 17/18mm. BLU 16766077 PRINTED CIRCUIT BOARD BMBC w/DISPLAY 44860006 SAFETY THERMOSTAT 95C° X EL.TB 1NT 28860014 WATER PRESSURE GAUGE M3A-ABS 40 0-4 G1/8C/D+C 44860045 SAFETY THERMOSTAT 125° LS1 INOX 18880018 TRANSFORMER 10Hz 230VAC 30/3200Y 48950019 EXPANSION VESSEL LT.8 28960032 DIVERTER VALVE w/MOLEX ATV-03 M.PLEX 28960034 DIVERTER VALVE MOTOR NYM-16H 12960039 3 BAR PRESSURE RELIEF VALVE -HTG CIRCUIT Table 9: Short parts list TR05A153.B1107 63 MAINTENANCE INSTRUCTIONS 6.10.2 MULTIPLEX unit 28640066 28540022 46891016 46891016 28641026 28431035 28640068 46891022 28431045 28960032 28431050 28430003 28431039 28735007 28330030 28200047 42835046 28610004 28431050 28431050 28641027 28430002 28891034 28960034 28540022 28431039 28540022 28641024 28540022 28431050 12960039 28432076 28431059 28431050 28261037 28590015 28540032 28641023 28432048 28640075 28540023 28641006 28431051 28261027 28431050 28261034 28540032 Figure 56: Multiplex assembly TR05A153.B1107 64 28860014 28410016 MAINTENANCE INSTRUCTIONS 28200047 PLATE EXCHANGER 20 PLATES 28621027 PUMP MANIFOLD MULTIPLEX 2006 28261034 DHW OUTLET CONNECTION – INSTANTANEOUS MOD. - M.PLEX MOD.2006 28261037 COLD WATER HEATING FLOW CONNECTION - M.PLEX 2006 GB 28330030 SENSOR HOLDER – PUMP CONNECTION BODY M.PLEX 28410016 FLOWSWITCH FILTER 28430002 WASHER D.18.5x10.2x2 1/2" AFM34 28430003 WASHER D.15x8x2 3/8" AFM34 28431051 BY PASS O-RING 28431035 3 WAY VALVE WASHER 28431039 PLATE EXCHANGER O-RING 28431045 3 WAY VALVE MOTOR O-RING MULTIPLEX 28431050 SEAL O-RING 28431059 WASHER EPDM 80 SH M.PLEX 16x24x2,5 28432048 OR 4081 EPDM Di18,68x3,53 28432076 OR EPDM 17,00x4 28540022 FIXING CLIP 28540023 BYPASS SPRING 28540032 FIXING CLIP – STAINLESS STEEL 28590015 WATER PRESSURE SWITCH PC 5411 - BRASS 28610004 FLOWSWITCH PISTON 28640066 FLOWSWITCH CAP MULTIPLEX 28640068 3 WAY VALVE UPPER SECTION FOR ISTANTANEOUS MODELS 28640075 BYPASS MULTIPLEX ZYTEL 70G30 28641006 BYPASS BUSH IN NYLON 66 28641023 PUMP MANIFOLD CONNECTION BEND M.PLEX 2006 28641024 PUMP CONNECTION SECTION M.PLEX 2006 28641026 3 WAY VALVE BOTTOM SECTION M.PLEX 2006 ZYTEL 28641027 FLOWSWITCH GROUP FOR ISTANTANEOUS MODELS 2006 28735007 DHW-HEATING SENSOR 1/8" WHITE 42835046 BYPASS PIPE D.8 28860014 WATER PRESSURE GAUGE M3A-ABS 40 0-4 PB120417 46891016 GALVANISED SCREW 5x16 T.C. 3-LOBE CROSSHEAD DIN 7687 46891022 GALVANISED SCREW 5x13 T.C. 3-LOBE CROSSHEAD DIN 7687 28891034 SCREW 5x14 FOR PLATE HEAT EXCHANGER 28960032 3 WAY VALVE C/MOLEX ATV 03 MULTIPLEX 28960034 3 WAY VALVE MOTOR MULTIPLEX 12960039 3 BAR PRESSURE RELIEF VALVE M.PLEX 2006 - OR4081E - OR17,00x4 Table 10: Multiplex assembly parts list TR05A153.B1107 65 OPTIONAL CONTROLS 7 OPTIONAL CONTROLS 7.1 External controls, programmers and room thermostats All external controls used with this appliance MUST BE ZERO-VOLT SWITCHING ONLY! If mains voltage, i.e. a switched live, is fed to the control terminals THE APPLIANCE WILL NOT FUNCTION and could be SEVERELY DAMAGED! 7.1.1 Appliance connections To fit a programmer, room thermostat or other external controls: • Isolate the electricity, water and gas supplies to the appliance; • Remove the front casing panel of the boiler (refer to 6.3 for guidance); Remove terminal block cover A of the control panel (see Figure 57); • Remove the link between the two terminals marked Ta on terminal block B (see Figure 57); • Connect the two wires from the programmer, room thermostat or controls to the terminals marked Ta; • Replace terminal block cover A. N Ta Ta Se Se • B L External Controls: A - Programmer - Room thermostat - S-Plan system Figure 57: Connection of external controls TR05A153.B1107 66 7.1.2 S-Plan wiring schematic Figure 58: S-Paln wiring schematic TR05A153.B1107 Heating Zone Hot Water Cylinder Room Thermostat 67 Add more valves & programmers as required Neutral 2-port zone valves Zone valve microswitches Zero-volt Switching Circuit Boiler Terminal Block OPTIONAL CONTROLS Permanent Live Cylinder Thermostat OPTIONAL CONTROLS 7.2 Weather compensating controls An Outside Sensor 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 Se 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. 7.2.1 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 (see Figure 59); • Connect the two wires of the sensor to the connections marked Se on terminal block B (see Figure 59); • Replace terminal block cover A. • 2 M1 1 N Ta Ta Se Se Outside temperature sensor L B External Controls: A - Programmer - Room thermostat - S-Plan system Figure 59: Outdoor Sensor connection 7.2.2 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 60, 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 Section 5.6). TR05A153.B1107 68 OPTIONAL CONTROLS Tm 7 8 9 40 MAX 80 75 70 65 35 60 55 50 30 45 40 35 25 MIN 30 5 4 3 2 1 0 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 Outside Temperature, Te / ºC Figure 60: Weather compensating control profiles TR05A153.B1107 6 Standard Temperature Range Reduced Temperature Range CH Flow Temperature, Tm / ºC 69 1 0 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 -12 -13 -14 -15 THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK INSTALLATION, COMMISSIONING & SERVICING RECORD INSTALLER & COMMISSIONING ENGINEER DETAILS Installer Details Company Name Installation Date Address CORGI Registration No. CORGI ID Serial No. Commissioning Engineer Details (if different from Installer) Company Name Installation Date Address CORGI Registration No. CORGI ID Serial No. APPLIANCE & CONTROL DETAILS Boiler Make & Model Serial No. SEDBUK Efficiency Location New System or Replacement boiler Controls To comply with Building Regulations, each section must have a tick in one or more boxes Requirement Measures Provided Room Thermostat and Programmer / Timer Cylinder Thermostat and Programmer / Timer 1. Time and Temperature Control to Heating 2. Time and Temperature Control to Hot Water 3. Heating Zone Valves Fitted 4. Thermostatic Radiator Valves Fitted 5. Automatic Bypass to System Fitted 6. Boiler Interlock Provided TR05A153.B1107 Programmable Room Thermostat Combi Boiler Not Required Not Required % INSTALLATION, COMMISSIONING & SERVICING RECORD COMMISSIONING PROCEDURE INFORMATION For All Boilers Has the system been flushed in accordance with the boiler manufacturer’s instructions? Yes No Yes No What cleanser was used? Has an inhibitor been added? Which inhibitor was used? For central heating mode, measure and record: Heat Input kW Burner Operating Pressure mbar Central Heating Flow Temperature ºC Central Heating Return Temperature ºC For Combination Boilers Only Has a water scale reducer been fitted? Yes No What type of scale reducer has been fitted? For domestic hot water mode, measure and record: Heat Input kW Maximum Burner Operating Pressure mbar Maximum Operating Water Pressure bar Cold Water Inlet Temperature ºC Hot Water Outlet Temperature ºC Water Flow Rate at Maximum Setting l/min For Condensing Boilers Only Has the condensate drain been fitted in accordance with the manufacturer’s instructions? Yes No For All Installations Does the heating and hot water system comply with the appropriate Building Regulations? Yes Has the appliance and associated equipment been installed and commissioned in accordance with the manufacturer’s instructions? Yes Have you demonstrated the operation of the appliance and system controls to the customer? Yes Have you left all the manufacturer’s literature with the customer? Yes Competent Person’s Signature Customer’s Signature (To confirm demonstrations of equipment and receipt of appliance instructions) TR05A153.B1107 INSTALLATION, COMMISSIONING & SERVICING RECORD Service 1 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Service 2 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Signature Signature Service 3 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Service 4 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Signature Signature Service 5 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Service 6 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Signature Signature Service 7 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Service 8 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Signature Signature Service 9 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Service 10 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Signature Signature TR05A153.B1107 THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK WARMFLOW Engineering Company Limited Lissue Industrial Estate, Moira Road, Lisburn BT28 2RF Tel: 028 9262 1515 Fax: 028 9262 0869 Warmflow Customer Care Centre UK ROI Email 028 9262 1515 048 9262 1515 [email protected] THE TECHNICAL DATA AND MEASUREMENTS ARE PROVIDED FOR INFORMATION PURPOSES ONLY AND ARE NOT BINDING. THE COMPANY RESERVES THE RIGHT TO APPLY VARIATIONS WITHOUT PRIOR NOTIFICATION. NEITHER WILL THE COMPANY BE HELD RESPONSIBLE FOR ANY INACCURACIES IN THIS HANDBOOK DERIVING FROM PRINTING OR TRANSLATION ERRORS. E+OEALL RIGHTS RESERVED. NO PART OF THIS DOCUMENT MAY BE REPRODUCED, MEMORISED IN ANY FILING SYSTEMS OR TRANSMITTED IN ANY FORM WHATSOEVER, INCLUDING ELECTRONIC, MECHANICAL, PHOTOCOPIES, RECORDINGS OR ANY OTHER MEANS WITHOUT THE COMPANY’S PRIOR WRITTEN APPROVAL. TR05A153.B1107