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 GS25A Gas premix system boiler SEDBUK TR05A140.B1107 TR05A140.B1107 CONTENTS 1 USER INSTRUCTIONS 1.1 Boiler controls 1.1.1 Control panel layout 1.1.2 Operating the appliance 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 and display 3.6.1 Layout 3.6.2 Boiler operation 3.6.3 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 Central heating circuit 4.4.2 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 Twin pipe flue system – Ø 80/80 (Kit H) 5 COMMISSIONING 5.1 5.2 5.3 5.4 5.5 5.6 TR05A140.B1107 General warnings Filling the system Flushing the system Filling the condensate trap Starting the boiler Control parameters 3 3 3 3 4 4 5 5 5 7 8 8 9 10 11 12 13 13 13 14 15 15 16 17 17 18 19 19 20 21 22 22 23 24 25 26 27 28 29 30 31 31 32 33 33 34 35 CONTENTS 5.7 Control parameter adjustment 5.7.1 Accessing the parameters menu 5.7.2 Adjusting the parameters 5.8 Gas data 5.8.1 Technical reference tables 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 Maintenance operations 6.6.1 Primary heat exchanger and burner unit 6.6.2 Ignition and ionisation electrodes 6.6.3 Safety thermostat 6.6.4 Heating sensor 6.6.5 Gas valve 6.6.6 Circulating pump motor body 6.6.7 Electric fan 6.6.8 Expansion vessel 6.6.9 Modulation circuit board 6.6.10 Electric fan circuit board 6.6.11 Primary heat exchanger replacement 6.7 Wiring diagram 6.8 Troubleshooting 6.8.1 Error codes 6.9 Parts lists 6.9.1 Main components 7 OPTIONAL CONTROLS 7.1 External controls, programmers and room thermostats 7.1.1 Appliance connections 7.1.2 S-Plan wiring schematic TR05A140.B1107 36 36 37 42 42 43 43 43 44 44 44 44 45 45 46 47 48 48 48 49 49 50 50 51 51 51 52 53 53 54 54 55 55 55 56 GENERAL INFORMATION 1 USER INSTRUCTIONS 1.1 Boiler controls 8 7 1.1.1 Control panel layout 1. ON/OFF button 2. Central Heating Control knob 3. button 4. S button 5. button ON / OFF 6. Mains supply terminal board 7. Digital LCD display 8. Programmer location (N/A) 1 2 3 4 5 Figure 1: Control Panel 1.1.2 Operating the appliance Operation Instruction Switching the boiler on Press the ON/OFF button (1) Adjusting the Central Heating temperature Turn the Central Heating Control knob (2): - the temperature setting will appear on the display Switching the boiler off Press the ON/OFF button (1) Table 1: Control panel display TR05A140.B1107 3 6 GENERAL INFORMATION 1.2 Topping up the system (Error Code H20) If the water pressure in the central heating circuit falls below 0.3 bar, the boiler will go to lock out (stop working) and Error Code H2O will appear on the display. This could be caused be a leak in the system, if air is bled from a radiator or if a radiator is replaced. The system will then need to be topped up. To top up the system: • Let the boiler and radiators cool down; • Connect the filling loop (usually located near the boiler); • Open the filling loop valve (or valves); • Fill the system until the pressure gauge (located on the underside of the boiler) reads 1 bar; • 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 TR05A140.B1107 0800 111 999 0800 002 001 1850 20 50 50 4 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. TR05A140.B1107 5 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.) TR05A140.B1107 6 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. TR05A140.B1107 7 TECHNICAL CHARACTERISTCS 3 TECHNICAL CHARACTERISTICS 3.1 Technical data Model GS25A Appliance Type Appliance Category Heat Input max Heat Input min Heat Output max (50/30°) Efficiency 100% (full load 50/30°) Efficiency 30% (partial load 50/30°) Heat Output max - 80/60°C (Non condensing) Heat Output min - 80/60°C (Non condensing) Efficiency 100% (full load 80/60°) Efficiency 30% (partial load 80/60°) GAS DIRECTIVE 92/42/ECC - Efficiency marking SEDBUK kW kW kW % % kW kW % % stars band C13, C33, C43, C53, C63, C83 II2H3+ 25 9 26.67 106.7 106.3 24.6 8.73 98.4 100.1 4 A Central Heating (CH) Circuit CH water temperature setting (min-max) Max. CH working temperature Expansion vessel capacity Max. CH working pressure Min. CH working pressure °C °C litres bar bar 30-80 80 8 2.5 0.3 Dimensions Width Height Depth Weight (net) mm mm mm kg 410 730 285 46 Ø Ø Ø 3/4" (22mm tail supplied) 3/4” (22mm tail supplied) 3/4” (22mm tail supplied) Ø mm m Ø mm m Ø mm m Ø mm m Ø mm m 60/100 5 80/125 7 60/100 5 80/125 7 80/80 50 mbar m3/h 20 2.65 mbar kg/h 30 1.97 mbar kg/h 37 1.94 V/Hz W IP 230/50 170 X4D Hydraulic Connections CH Flow connection CH Return 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 Specifications Power supply Electrical power consumption Electrical protection Table 2: Technical data TR05A140.B1107 8 TECHNICAL CHARACTERISTCS 3.2 Dimensions 111.5 187 48.5 111.5 730 313 730 48.5 ON / OFF 148 182 285 31 285 132 49 105 HF G HR LEGEND 163 137 110 Figure 2: Dimensions TR05A140.B1107 9 HR HEATING RETURN 22mm HF HEATING FLOW 22mm G GAS 22mm SC CONDENSATE DRAIN 25mm TECHNICAL CHARACTERISTCS 3.3 Internal components 17 16 1 4 2 3 13 12 7 6 11 14 10 22 24 23 16 18 8 5 9 19 20 15 21 Figure 3: Internal components LEGEND 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. PRIMARY CONDENSING HEAT EXCHANGER PREMIX BURNER UNIT (GAS MANIFOLD + BURNER) HEAT EXCHANGER CONDENSATE DRAIN CONNECTION IONISATION ELECTRODE IGNITION ELECTRODE FAN VENTURI IGNITION TRANSFORMER ELECTRONIC GAS VALVE 3 BAR PRESSURE RELIEF VALVE – HEATING CIRCUIT AUTOMATIC AIR VENT VALVE HEATING SAFETY THERMOSTAT HEATING SENSOR PUMP WITH AIR VENT WATER PRESSURE SWITCH FLUE HOOD FLUE SAFETY THERMOFUSE EXPANSION VESSEL ROOM SEALED CHAMBER BULKHEAD CONDENSATE TRAP WATER PRESSURE GAUGE SYSTEM DRAIN VALVE CONDENSATE DRAIN PIPE AUTOMATIC BYPASS PRIMARY HEAT EXCHANGER MANUAL AIR VENT VALVE TR05A140.B1107 10 25 4 5 1 2 12 6 9 19 11 14 TECHNICAL CHARACTERISTCS 3.4 Function diagram LEGEND 16 17 13 12 8 2 4 18 1 5 3 7 6 19 9 1. PRIMARY CONDENSING HEAT EXCHANGER 2. PREMIX BURNER UNIT (GAS MANIFOLD & BURNER) 3. HEAT EXCHANGER CONDENSATE DRAIN PIPE 4. IONISATION ELECTRODE 5. IGNITION ELECTRODE 6. FAN 7. VENTURI 8. IGNITION TRANSFORMER 9. ELECTRONIC GAS VALVE 10. 3 BAR PRESSURE RELIEF VALVE - HEATING CIRCUIT 11. AUTOMATIC AIR VENT VALVE 12. HEATING SAFETY THERMOSTAT 13. HEATING SENSOR 14. PUMP WITH AIR VENT 15. WATER PRESSURE SWITCH 16. FLUE HOOD 11 20 14 10 22 23 17. FLUE SAFETY THERMOFUSE 18. EXPANSION VESSEL 19. ROOM SEALED CHAMBER 20. CONDENSATE TRAP 21 21. WATER PRESSURE GAUGE 15 22. AUTOMATIC BYPASS SC HR G 23. CONDENSATE DRAIN PIPE 24. SYSTEM DRAIN VALVE HF Figure 4: Function diagram HR HEATING RETURN 22mm HF HEATING FLOW 22mm G GAS 22mm SC CONDENSATE DRAIN 25mm TR05A140.B1107 11 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 TR05A140.B1107 12 1600 TECHNICAL CHARACTERISTCS 3.6 Control panel and display The appliance MUST be supplied with a permanent live in order for the boiler’s protective functions to operate. These functions include frost protection, post-ventilation, pump overrun and pump & 3-way valve inactivity protection. On first connection to the power supply, the appliance must be switched on using the ON/OFF button on the control panel to activate all of the above protective features. The appliance can then be switched off but the protective features will remain active. 8 3.6.1 Layout 7 1. ON/OFF button 2. CH Control knob 3. DISPLAY button 4. S SERVICE button 5. MODE button 6. Mains supply terminal board ON / OFF 7. Digital LCD display 8. Programmer location (N/A) 1 3.6.2 Boiler operation 2 3 4 5 Figure 6: Control Panel Mode / Control Input Display will show: Boiler switched off OFF Press ON/OFF button (to switch the boiler on) Primary circuit temperature in ºC Icon – lit when appliance switched on CH controls call for heat Primary circuit temperature in ºC Icon – flashes whilst CH mode is active CH Control knob turned CH set point temperature in ºC – displayed for 3 seconds SERVICE button pressed & held for 7 seconds Function Code 07 – flashes whilst activated (see Section 3.6.3) Boiler protection function activated (automatically) Function Code 08 – flashes whilst activated (see Section 3.6.3) Boiler locked out Error Code – flashes whilst locked out (see Section 6.8.1) Table 3: Control panel display TR05A140.B1107 13 6 TECHNICAL CHARACTERISTCS 3.6.3 Function codes Code Function Description Operates the boiler at maximum CH output for 15 minutes without modulation. 07 Commissioning Mode Activated by pressing and holding the S button for 7 seconds. Deactivated by switching the appliance off. 08 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. Table 4: Function codes TR05A140.B1107 14 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. TR05A140.B1107 15 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 TR05A140.B1107 16 INSTALLATION INSTRUCTIONS 4.3 Installing the boiler ■ L Y H ■ 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. B ■ MINIMUM DISTANCE IN mm LX HY AL MX Xodel Y Y L H A 60 450 1000 200 RKR 60 1000 60 200 410 60 29 60 60 410 BH B 300 1000 300 A B 200 300 In order to allow access to the interior of Figure 8: Access clearances the boiler for maintenance purposes, it is important that the necessary clearances indicated in Figure 8 are respected. For ease of installation, the boiler is supplied with a template to enable the pipe connections to be positioned prior to fixing the appliance to the wall. To install the boiler, proceed as follows (see Figure 9): 1 Use a spirit level to mark a horizontal line on the wall where the boiler is to be fitted. 2 Position the top of the template along the line. Mark the centres of fixing locations and the positions of the water and gas pipes. 3 Remove the template and install the gas supply pipe and the central heating pipes using the fittings supplied with the boiler. 4 Install the hanging bracket then fix the boiler to the wall and connect the pipes. Figure 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. TR05A140.B1107 17 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. Isolation valves must be installed on the CH circuit in order to facilitate all maintenance and service operations where the boiler needs to be drained. The boiler is supplied with a fittings kit (see Figure 11) complete with isolation valves and copper tails. ■ To prevent vibration and noise coming from the system, do not use pipes of reduced diameter, short radius elbows or severe restrictions. 105 The CH pipes must be adequately earthed. However, the appliance must also be provided with an adequate earth. Pipe work is NOT suitable for this purpose. 49 HR 148 182 G 31 HF Figure 10: Location of connections Ø 22 mm HF Ø 15 22 mm G Ø 22 mm HR Figure 11: Fittings kit LEGEND TR05A140.B1107 HR HEATING RETURN 22mm HF HEATING FLOW 22mm G GAS 22mm CD CONDENSATE DRAIN 25mm 18 INSTALLATION INSTRUCTIONS 4.4.1 Central heating circuit The boiler is designed for use in a sealed central heating system in accordance with the requirements of BS 5449 and BS 6798. The system should be designed to operate with flow temperatures of up to 82°C. When designing the system, the pump head, expansion vessel size, mean radiator temperature, etc. must all be taken into account. The boiler is supplied with the following components built in:Pressure relief valve – complies with BS 6759 and set is to operate at 3 bar. The outlet connection of the pressure relief valve must be connected via a tundish to a safe visible discharge. The manufacturer will not be held responsible for flooding caused by the operation of the pressure relief valve in the case of system overpressure where adequate drainage has not been provided. Pressure gauge – indicates the system pressure. Expansion vessel – conforms to BS 7074:1 and has a volume of 8 litres. If the total system volume requires more than 8 litres of expansion capacity, an additional expansion vessel will be required. Bypass – incorporated within the boiler. However, where all radiators are fitted with thermostatic radiator valves, it is recommended an additional automatic system bypass is fitted. 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 4.4.2 Filling the central heating system All fittings used in filling the system must be suitable for mains pressure applications. Filling of the system must be carried out in an approved manner (in the UK, refer to Guidance G24.2 and Recommendation R24.2 of the Water Regulation Guide) and in accordance with the instructions in Section 5.2. The system should be filled via a temporary filling loop connection as shown in Figure 13. After filling, the flexible hose of the filling loop must be disconnected. The filling loop should be installed such that it can be easily reconnected in order to top up the system if any water is lost (e.g. due to leakage or after replacing a radiator). Drain cocks (to BS 2879) must be fitted to the lowest points in the system to allow it to be completely drained. A corrosion inhibitor must be added to the CH circuit in order to guarantee the life of the appliance. In hard water areas, a combined corrosion inhibitor and softener must be used. The system pre-charge pressure (cold) should be 1 bar. TR05A140.B1107 Figure 13: Filling loop layout 19 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 TR05A140.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. 20 INSTALLATION INSTRUCTIONS 4.6 Gas connection The connection to the gas supply must be carried out by professionally qualified personnel in accordance with relevant standards. When connecting the boiler to the gas supply pipe, only use appropriate washers and gas fittings. The use of hemp, PTFE tape and similar materials is not allowed. In areas prone to Copper Sulphide build-up in gas supply pipes (such as in Northern Ireland) an in-line filter should be installed upstream of the appliance. Before installing the boiler, check that: ■ The pipe work is appropriately sized for the flow rates required and the pipe lengths installed, and must be fitted with all the safety and control devices required by current standards; ■ The gas supply line must be a minimum of a 22 mm diameter pipe with a direct supply from meter to boiler and comply with current standards and regulations; ■ Check the internal and external seals of the gas supply system; ■ A gas shut-off valve must be installed upstream of the appliance; ■ An in-line filter is installed, where necessary, and is free from blockage; ■ Before starting up the boiler, make sure that the type of gas corresponds to that for which the appliance has been configured (see gas type label inside the boiler). Conversion of the appliance from natural gas to LPG must only be carried out by qualified personnel; ■ Check that the gas supply pressure is between the values stated on the rating plate (see gas type label inside the boiler); ■ Prior to installation, it is good practice to ensure that there are no machining residues on the gas supply pipe. TR05A140.B1107 21 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. TR05A140.B1107 22 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. N 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 7. blue green/yellow L ON / OFF Figure 15: Power supply connections TR05A140.B1107 A B 23 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 C53 C13 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 0 4 5 0 6 0 7 0 8 0 C83 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. TR05A140.B1107 24 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. TR05A140.B1107 25 300 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 Ø 60/100 MAXIMUM FLUE LENGTH = 5 m * The flue length is the total length of the flue excluding the first bend. The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below). Ø 80/125 x 90° bend = 0.8 m Ø 80/125 x 45° bend = 0.5 m * If a flue length of above 5 metres is required, use the Ø 80/125 system. Figure 18: Ø 60/100 Horizontal Kit K 132 97 100 60 163 48.5 313 111.5 187 48.5 111.5 Figure 19: Ø 60/100 Horizontal Kit K dimensions TR05A140.B1107 26 INSTALLATION INSTRUCTIONS 4.8.3 Horizontal coaxial balanced flue – Ø 80/125 FOR CONDENSING BOILERS ONLY Ø 80/125 MAXIMUM FLUE LENGTH = 7 m * The flue length is the total length of the flue excluding the first bend. The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below). Ø 80/125 x 90° bend = 0.8 m Ø 80/125 x 45° bend = 0.5 m * If a flue length of above 7 metres is required, use the Twin Pipe system. 132 163 15 97 125 80 Figure 20: Ø 80/125 Horizontal Kit 48.5 313 111.5 187 48.5 111.5 Figure 21: Ø 80/125 Horizontal Kit dimensions TR05A140.B1107 27 INSTALLATION INSTRUCTIONS 4.8.4 Vertical coaxial balanced flue – Ø 60/100 (Kit V) FOR CONDENSING BOILERS ONLY Ø 60/100 MAXIMUM FLUE LENGTH = 5 m * The flue length is the total length of the flue excluding the first bend. The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below). Ø 80/125 x 90° bend = 0.8 m Ø 80/125 x 45° bend = 0.5 m * If a flue length of above 5 metres is required, use the Ø 80/125 system. max. 5.00 mt. Figure 22: Ø 60/100 Vertical Kit V Ø60 Ø100 Ø60 Ø100 163 131 Figure 23: Ø 60/100 Vertical Kit V dimensions TR05A140.B1107 28 INSTALLATION INSTRUCTIONS 4.8.5 Vertical coaxial balanced flue – Ø 80/125 FOR CONDENSING BOILERS ONLY Ø 80/125 MAXIMUM FLUE LENGTH = 7 m * The flue length is the total length of the flue excluding the first bend. The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below). Ø 80/125 x 90° bend = 0.8 m Ø 80/125 x 45° bend = 0.5 m * If a flue length of above 7 metres is required, use the Twin Pipe system. max. 75.00 mt. Figure 24: Ø 80/125 Verical Kit Ø60 Ø100 Ø60 Ø100 163 131 Figure 25: Ø 80/125 Verical Kit dimensions TR05A140.B1107 29 INSTALLATION INSTRUCTIONS 4.8.6 Twin pipe flue system – Ø 80/80 (Kit H) FOR CONDENSING BOILERS ONLY Ø 80/80 MAXIMUM FLUE LENGTH = 50 m The flue length is the total length of both the intake and exhaust sections excluding the first bend of each. The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below). Ø 80 x 90° bend = 1.5 m Ø 80 x 45° bend = 1.2 m Figure 26: Ø 80/80 Twin Pipe Kit H 131 137 48.5 313 111.5 187 48.5 111.5 Figure 27: Ø 80/80 Twin Pipe Kit H dimensions TR05A140.B1107 30 122 106 80 80 163 COMMISSIONING INSTRUCTIONS 5 COMMISSIONING 5.1 General warnings The following operations must be carried out by professionally qualified personnel, registered in accordance with current legislation. Reference should be made to BS 5449:5 - Commissioning. The boiler leaves the factory pre-set and tested for burning Natural Gas (Methane). Nevertheless, when starting the boiler for the first time, make sure that the information on the rating plate corresponds to the type of gas being supplied to the boiler. Once the system has been filled and the necessary adjustments made, remember to tighten the screws of the gas valve test point and make sure that there are no gas leaks from the test point and from any pipe fittings upstream of the gas valve. ■ Preliminary operations Switching the boiler on for the first time means checking that the installation, regulation and operation of the appliance are correct. The commissioning engineer MUST check, referring to the previous sections of this manual, the following:• That the data on the data plate corresponds to that of the mains supply networks (gas, electricity, water); • That the power supply voltage to the boiler complies with the data plate (230 V – 50 Hz) and that the live, neutral and earth wires are correctly connected. Also, that the earth connection is sound and that the appliance is effectively earthed; • That the gas supply is correctly sized for the flow rate required by the boiler and that it is fitted with all the safety and control devices as lay down by current regulations; • That all mechanical connections are sound and have not become loose during transportation and handling; • That the seals on the gas supply pipe from the mains are sound, and that the meter does not register any flow of gas; • That the flue system (air intake and exhaust ducts) is installed correctly and in line with current law and national and local standards; • The all permanent combustion air and ventilation openings as required by current law for the type of appliances installed are provided and are not blocked; • That the condensate drainage system(s) are installed correctly and in line with current law and national and local standards; • That the condensate drainage system, including outside the boiler (condensate collection devices), allows the condensate to flow freely to the drain. Check that no exhaust fumes could discharge into the drainage system; • That there are no flammable materials or liquids in the immediate vicinity of the boiler. The commissioning engineer must then:• Flush out the central heating circuit (see Section 5.3); • Turn the gas supply on and purge according to BS6891. • Test for gas soundness (let-by and tightness). TR05A140.B1107 31 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 4.4.2). AIR VENT VALVE AIR VENT VALVE PLUG PUMP Check the properties of the water supply and use appropriate treatment agents if the mains water has a hardness rating more than 17.5 °Ck. 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: • Slacken the air vent valve plug to allow air to escape from the system (see Figure 28); • Open the main domestic water supply valve; • Open the external filling loop; • Unscrew the pump plug to remove any trapped air, check that the pump is free then re-tighten it when water starts to flow out; • Unscrew the manual air vent valve located in the top left hand corner of the primary heat exchanger until air begins to escape. When water begins to flow out, screw the valve tightly closed. • Open the air vents on the radiators and monitor the air evacuation process. When water starts to flow out of the radiators, close the air vents; • Use the pressure gauge M (see Figure 29) to monitor the system pressure. Close the external filling loop when the system pressure reaches 1 bar and check that Error Code H2O is NOT displayed on the control panel display (see Section 3.6); Figure 28: Air vent and pump bleed plugs RS • 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. TR05A140.B1107 Figure 29: Pressure gauge and boiler drain 32 M COMMISSIONING INSTRUCTIONS 5.3 Flushing the system Failure to flush and add inhibitor to the system will invalidate the warranty. The system must be thoroughly drained and flushed out using flushing agents/descalers that comply with BS7593. When refilling the system, appropriate corrosion inhibitors and softening agents must be added. a. Fill the boiler as per the filling instructions; b. Using a drain cock on the lowest point of the system, allow the water to drain from both the system and boiler; c. To flush the system correctly, turn off all radiators, open the filling loop and drain cock simultaneously and allow the water to flow through the boiler; d. For each radiator on the system in turn, open the radiator valves, allowing water to flow through, then turn that radiator off. Repeat for all the radiators on the system; e. Close the drain cock, re-open all radiators and fill the system following the instructions in Section 5.2; a. Continue to fill the system until the pressure gauge reaches 1 bar. 5.4 Filling the condensate trap The condensation trap MUST be pre-filled when starting the boiler for the first time in order to prevent flue gases from escaping via the drain. The filling operation is carried out as follows (see Figure 30): • Remove plug T and fill the trap S three quarters full with water; • Replace plug T and connect the drainpipe P. The trap should be cleaned after a few months of boiler operation, as deposits/residues drawn out of the heat exchanger may impair the operation of the trap. T S Figure 30: Condensate Trap TR05A140.B1107 33 COMMISSIONING INSTRUCTIONS 5.5 Starting the boiler Once the system has been flushed and filled, proceed as follows: Gas Type • Check that the exhaust flue is free of obstructions and correctly connected to the boiler; Natural Gas (Methane) – G 20 9.4 LPG (Butane) – G 30 10.9 LPG (Propane) – G 31 11.0 CO2 Concentration / % • Check that all isolation valve are open (CH Table 5: Correct gas analyser readings circuit and gas) • Switch on the power supply to the boiler and ensure that the system controls are calling for heat; PF • Switch the boiler on using the ON/OFF button on the Control Panel (see Section 3.6) and ensure any system controls are calling for heat. After a few seconds the circulating pump will start to run; • The automatic ignition system will then attempt to fire the burner. The system will make 3 attempts and then go to lock-out if unsuccessful. It may be necessary to repeat the process a few times in order to eliminate all the air from the gas supply line. To repeat the process, wait approximately three minutes then reset the appliance by switching the boiler off then on using the ON/OFF button on the Control Panel; • With the boiler ignited, if the system still emits noises, the above process must be repeated until all the air has been removed; V • Check the pressure in the heating circuit using the pressure gauge (see Section 5.2). If the pressure has fallen, re-open the filling loop until the pressure gauge reads 1 bar. Check that Error Code H2O is NOT displayed on the Control Panel display. On completion, close the filling loop; • Unscrew the plug and insert an analyser in the exhaust sampling point PF (see Figure 31 – twin pipe flue system depicted) to check the CO2 value. The value should correspond Figure 31: Flue sampling and commissioning points to those in Table 5; • If the CO2 value does not correspond to those in the table, adjust screw V on the venturi (see Figure 31) clockwise to reduce the CO2 value or anticlockwise to increase it. TR05A140.B1107 34 COMMISSIONING INSTRUCTIONS 5.6 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 - - Not applicable to this appliance 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 - - Not applicable to this appliance 9 - - Not applicable to this appliance 10 - - Not applicable to this appliance 11 - - Not applicable to this appliance 12 - - Not applicable to this appliance 13 - - Not applicable to this appliance 14 Burner type 00 01 02 03 Atmospheric Premix 25 kW Premix 29-34 kW Premix 50 kW 15 - - Not applicable to this appliance 16 - - Not applicable to this appliance 17 Minimum fan speed 33-202 (default = 66) Expressed in Hertz (Hz) (Default = 66 Hz) 18 Maximum fan speed 33-202 (default = 162) Expressed in Hertz (Hz) (Default = 162 Hz) 19 Minimum fan speed (in CH mode) 33-202 (default = 66) Expressed in Hertz (Hz) (Default = 66 Hz) 20 Maximum fan speed (in CH mode) 33-202 (default = 162) Expressed in Hertz (Hz) (Default = 162 Hz) 21 Ignition sequence fan speed 33-202 (default = 110) Expressed in Hertz (Hz) (Default = 110 Hz) 22 Fan speed display mode 00 01 Off On (displays fan speed for 10 minutes) Table 6: Control Parameters NOTES Factory default values highlighted in bold. Parameters 1 and Parameter 14 highlighted in grey only need to be adjusted when replacing the Modulation PCB. When the PCB is replaced and Parameter 14 is set to values 01, 02 or 03 the PCB will automatically set Parameters 17 through 22 to the factory default values stated above. TR05A140.B1107 35 COMMISSIONING INSTRUCTIONS 5.7 Control parameter adjustment 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 TR05A140.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. 36 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 TR05A140.B1107 37 COMMISSIONING INSTRUCTIONS Parameter 4 – CH pump mode Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Runs when controls call for heat 01 = Runs continuously when appliance is on Press and release the 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. 36 00 S 4 7 S Parameter 5 Not applicable to this appliance Parameter 6 – Short-cycling prevention (CH delay timer) Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = 0 x 5 seconds = 0 seconds (minimum) 90 = 90 x 5 seconds = 450 seconds (maximum) Note: Factory preset to 36 = 180 seconds Press and release the 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. 36 S 7 6 S 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 TR05A140.B1107 38 COMMISSIONING INSTRUCTIONS Parameters 8 through 13 Not applicable to this appliance 02 01 S 14 S Parameter 14 – Burner type Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Atmospheric burner (all outputs); 01 = Premix burner – 25 kW; 02 = Premix burner – 29-34 kW; 03 = Premix burner – 50 kW; Press and release the S button. The parameter number (14) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button. Parameters 15 and 16 Not applicable to this appliance TR05A140.B1107 39 COMMISSIONING INSTRUCTIONS 55 S 17 S 164 S 18 S 55 S 19 S 164 S 20 S TR05A140.B1107 Parameter 17 – Minimum fan speed Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 33 = 33 Hz (minimum) Maximum value determined by Parameter 18 Note: Factory preset to 66 = 66 Hz Press and release the S button. The parameter number (17) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button. Parameter 18 – Maximum fan speed Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: Minimum value determined by Parameter 17 202 = 202 Hz (maximum) Note: Factory preset to 162 = 162 Hz Press and release the S button. The parameter number (18) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button. Parameter 19 – Minimum fan speed (in CH mode) Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 33 = 33 Hz (minimum) Maximum value determined by Parameter 18 Note: Factory preset to 66 = 66 Hz Press and release the S button. The parameter number (19) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button. Parameter 20 – Maximum fan speed (in CH mode) Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: Minimum value determined by Parameter 17 202 = 202 Hz (maximum) Note: Factory preset to 162 = 162 Hz Press and release the S button. The parameter number (20) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button. 40 COMMISSIONING INSTRUCTIONS 110 S 21 Parameter 21 – Ignition sequence fan speed Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: Minimum value determined by Parameter 17 Maximum value determined by Parameter 18 Note: Factory preset to 110 = 110 Hz Press and release the S button. The parameter number (21) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button. S 00 S 22 Parameter 22 – Fan speed display mode Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Off 01 = On (Fan speed displayed for 10 minutes) Press and release the S button. The parameter number (22) will appear on the display. To store your changes, switch the appliance off then on again using the ON/OFF button. S TR05A140.B1107 41 COMMISSIONING INSTRUCTIONS 5.8 Gas data 5.8.1 Technical reference tables Gas Type CO2 Concentration / % Natural Gas (Methane) – G20 LPG (Butane) – G30 LPG (Propane) – G31 9.4 10.9 11.0 Table 7: Reference Carbon Dioxide concentrations Gas Type Minimum Fan Speed / Hz Maximum Fan Speed / Hz 66 60 60 162 149 149 Natural Gas (Methane) – G20 LPG (Butane) – G30 LPG (Propane) – G31 Table 8: 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 m /h 3 2.64 - - kg/h - 1.97 1.94 MJ/Nm Nominal Supply Pressure Consumption (15ºC; 1013 mbar) Consumption (15ºC; 1013 mbar) 3 Table 9: Reference gas data 26 24 22 Portata termica Heating Power kW kW 20 18 16 14 12 10 G30 G31 8 G20 6 4 2 0 0 10 20 30 40 50 60 70 80 90 Frequenza Fan Frequency HzHz Figure 32: Heating Output vs Fan Frequency TR05A140.B1107 42 100 110 120 130 140 150 160 170 MAINTENANCE INSTRUCTIONS 6 MAINTENANCE 6.1 General warnings All maintenance operations must be carried out by professionally qualified personnel. The frequency of boiler maintenance must comply with current law and should, in any case, be carried out annually. In order to guarantee the long life of the appliance, and in accordance with the current gas safety regulations, only use original spare parts. Before carrying out any type of maintenance operation, disconnect the appliance from the mains electricity supply and close the gas valve. 6.2 Boiler inspection In order to ensure that the boiler operates efficiently and safely, it is recommended that the appliance is inspected by a suitably competent technician at least once a year. The following must be checked annually: ■ The condition of the gas seals – replace where necessary; ■ The condition of the water seals – replace where necessary; ■ The condition of the combustion chamber and flame; ■ The combustion parameters – if necessary adjust in line with Sections 5.6 & 5.7; ■ The condition of the burner – remove any oxidation and clean if necessary; ■ The seal of the room sealed chamber is undamaged and positioned correctly; ■ The condition of the primary heat exchanger – clean if necessary; ■ The maximum and minimum modulation fan speeds and the modulation process itself – adjust if necessary; ■ The condition and operation of the ignition and gas safety systems – if necessary remove and clean any scaling from the ignition and flame detection electrodes, paying particular attention to replace them at the correct distance from the burner (see Section 6.6.2); ■ The heating safety systems: temperature and pressure limit devices – replace where necessary; ■ The system pre-charge pressure (should be 1 bar when cold) – if necessary refer to Section 5.2; ■ The integrity and operation of the flue system – correct where necessary; ■ That the mains electricity supply is safe and correctly rated (refer to Section 4.7) – correct where necessary; ■ The electrical connections inside the control panel – correct where necessary; ■ That the condensate drainage system is working correctly, including any parts of the system outside the boiler such as condensate collection devices along the length of the flue and/or any acid neutralising devices – correct where necessary; ■ That the condensate flows freely and that no exhaust fumes are present within the appliance or drainage system – correct where necessary. TR05A140.B1107 43 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 33). Figure 33: Front panel removal 6.3.2 Side panel removal • The side panels can only be removed after the front panel has been removed; • Remove the fixing screws at the front and lower edge of the side panel; • Grasp the bottom of the panel, move it sideways and then upwards (see Figure 34). Figure 34: 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 35); • Unscrew the four cover securing screws and remove the control panel rear cover. Figure 35: Control panel access TR05A140.B1107 44 MAINTENANCE INSTRUCTIONS 6.4 Draining the central heating system If the ENTIRE SYSTEM needs to be drained: • Switch on the boiler, select Heating Only Mode and allow the boiler to fire. Refer to Section 3.6 for how to operate the appliance; • Isolate the electricity and gas supplies to the boiler and wait for the boiler to cool down; • Connect a hosepipe to the system drain point and locate the other end of the hose in a suitable drain; • Open the boiler drain valve, located on the bottom of the pump manifold (see Figure 36); • Open the air vents on the radiators, starting with the highest and moving down the system to the lowest; • When the system has been drained, close the radiator air vents and the boiler drain Figure 36: Boiler drain valve valve. If ONLY THE BOILER needs to be drained: • Switch on the boiler, select Heating Only Mode and allow the boiler to fire. Refer to Section 3.6 for how to operate the appliance; • Isolate the electricity and gas supplies to the boiler and wait for the boiler to cool down; • Close the isolating valves on the heating circuit flow and return pipes; • Connect a hosepipe to the system drain point and locate the other end of the hose in a suitable drain; • Open the drain valve located at the bottom of the boiler on the pump manifold (see Figure 36); 6.5 Flushing the central heating system Refer to the detailed instructions in Section 5.3. TR05A140.B1107 45 MAINTENANCE INSTRUCTIONS 6.6 Maintenance operations Before carrying out any cleaning or part replacement operations, ALWAYS turn off the ELECTRICITY, WATER and GAS supplies to the boiler. Warmflow will not be held responsible for damage to any of the boiler’s components caused by non-compliance with this instruction. Section 6.3 gives instructions on accessing the boiler, removing casing panels, and accessing the control panel. Expansion vessel Primary heat exchanger Burner unit Ignition transformer Ionisation electrode Ignition electrode Heating sensor Safety thermostat Gas valve Electric fan Circulating pump Condensate trap Figure 37: Key components TR05A140.B1107 46 MAINTENANCE INSTRUCTIONS 6.6.1 Primary heat exchanger and burner unit • Isolate the electricity, water and gas supplies to the appliance; Primary heat exchanger • Disconnect the electrical connections of the electric fan; Premix burner unit • Disconnect and remove the pipe linking the gas valve to the venturi; • Disconnect and remove the gas feed pipe from the gas valve; • Unplug the ignition and ionisation electrode wires from the ignition control unit; • Unscrew the ring nut at the bottom of the room sealed chamber and remove the gas valve; • Unscrew the nuts securing the burner unit (consisting of a fan, manifold and burner) to the primary heat exchanger; B A Burner • Remove the burner unit, taking particular care not to remove the ceramic fibre board from the end of the heat exchanger; • Check that the burner is not affected by deposits, scaling or excessive oxidation. Check that all the holes in the burner are free; • Clean the electrodes carefully without altering their positions with respect to the burner; • Clean the burner cylinder using a non-metal brush and without damaging the ceramic fibre; Ignition electrode • Check the integrity of the seal on the cover of the burner; Ionisation electrode • Clean the heat exchanger using a suitable detergent for stainless steel, distributing the product on the spirals of the exchanger using a Figure 38: Primary heat exchanger and burner unit brush. Do not wet the ceramic fibre board. Wait a few minutes then remove the deposits using a Flue manifold Stainless steel non-metal brush. Remove the residues under exchanger coils running water; • Remove the condensate drain pipe and clean under running water; • Unscrew the joint to the condensate trap, remove the trap and wash under running water; • With the cleaning completed, re-assemble the components following the above procedure in reverse order; • Finally, check the boiler to make sure that all gas and exhaust joints are tight. Ceramic fibre Figure 39: Primary heat exchanger TR05A140.B1107 47 MAINTENANCE INSTRUCTIONS 6.6.2 Ignition and ionisation electrodes • Isolate the electricity, water and gas supplies to the appliance; Ionisation electrode • Unplug the electrode wires; • Slacken the fixing screws; • Remove the electrodes. When refitting the electrodes, check that the seals are not damaged and replace if necessary; • Reconnect the wires and reassemble the components following the above procedure in reverse order; Ignition electrode • Switch on the power supply and restart the appliance; If the boiler does not restart, check the positions of the electrodes. The ignition electrode should be positioned with a 10mm gap between it and the burner. The ionisation electrode must not be touching the burner surface. Figure 41: Ignition and ionisation electrodes 6.6.3 Safety thermostat • Isolate the electricity, water and gas supplies to the appliance; • Disconnect the connecting wire; • Unscrew the fixing screws and remove the thermostat; • Replace the thermostat and re-assemble the components following the above procedure in reverse order; Heating sensor 6.6.4 Heating sensor • Isolate the electricity, water and gas supplies to the appliance; Safety thermostat • Unplug the connecting wires; • Replace the sensor (expecting some water loss) and reconnect the wires; • Refill the system (see Sections 5.2) and check for any leaks. TR05A140.B1107 Figure 42: Safety thermostat and heating sensor 48 MAINTENANCE INSTRUCTIONS 6.6.5 Gas valve • Isolate the electricity, water and gas supplies to the appliance; • Disconnect and remove the gas pipe connecting the gas valve to the venturi; • Disconnect the gas feed pipe and valve ring nut at the bottom of the room sealed chamber; • Remove the couplings of the existing valve and fit to the new valve using new cork gaskets; • Replace the gas valve and reassemble the components following the above procedure in reverse order, replacing all the gas seals; Gas valve Couplings • Switch on the gas supply and check for any gas leaks using soapy water or leak detector spray; • Switch on the electricity and water supplies, switch on and fire the appliance and repeat the checks for leaks. Figure 43: Gas valve 6.6.6 Circulating pump motor body • Isolate the electricity, water and gas supplies to the appliance; • Drain the central heating circuit of the boiler (see Section 6.4); Pump impeller body • Use a 5 mm Allen key to unscrew the four screws securing the motor body to the impeller body; • Remove the motor body and check the condition of the gasket. Replace if necessary; • Replace the pump motor body and reassemble the components following the above procedure in reverse order; • Switch on the electricity, water and gas supplies; • Refill the system (see Sections 5.2) and check for any leaks. Figure 44: Circulating pump TR05A140.B1107 49 Pump motor body MAINTENANCE INSTRUCTIONS 6.6.7 Electric fan • Isolate the electricity, water and gas supplies to the appliance; Venturi • Remove and dismantle the entire burner unit (see Section 6.6.1); • Use an 8 mm spanner to unscrew the four nuts securing the electric fan to the gas manifold and then remove the electric fan, noting the positions of the washer and diaphragm (see Figure 45); • Remove the air intake duct, unscrew the two fixing screws from the venturi and remove the electric fan, paying particular attention not to damage the cork gasket. • Replace the electric fan and reassemble the Fan components following the above procedure in reverse order. Figure 45: Fan assembly • Switch on the electricity, water and gas supplies and check the soundness of the joint by measuring the CO2 levels; 6.6.8 Expansion vessel • Isolate the electricity, water and gas supplies to the appliance; • Drain the central heating circuit of the boiler (see Section 6.4); Fixing bracket • Use a 19 mm spanner to unscrew the vessel pipe coupling; • Unscrew the fixing screws and remove the upper mounting bracket. Remove the expansion vessel from the front of the boiler; Expansion vessel • Replace the expansion vessel and reassemble the components following the above procedure in reverse order; • Switch on the electricity, water and gas supplies; Vessel pipe • Refill the system (see Sections 5.2) and check for any leaks. Figure 46: Expansion vessel TR05A140.B1107 50 MAINTENANCE INSTRUCTIONS 6.6.9 Modulation circuit board • Isolate the electricity, water and gas supplies to the appliance; Modulation circuit board • Access the control panel (see Section 6.3); • Disconnect all the connectors, remove the control knobs from the front of the panel, unscrew the fixing screws and remove the modulation circuit board; • Replace the circuit board and reassemble the components following the above procedure in reverse order; • Switch on the electricity, water and gas supplies; • Program the boiler control parameters following the instructions in Sections 5.7. Electric fan circuit board Figure 49: Circuit boards 6.6.10 Electric fan circuit board • Isolate the electricity, water and gas supplies to the appliance; Modulation circuit board • Access the control panel (see Section 6.3); • Disconnect the two connectors from the fan circuit board, unscrew the two fixing screws and remove the board; • Replace the circuit board and reassemble the components following the above procedure in reverse order. Electric fan circuit board Figure 50: Circuit boards 6.6.11 Primary heat exchanger replacement • Isolate the electricity, water and gas supplies to the appliance; • Drain the central heating circuit of the boiler (see Section 6.4); • Remove and dismantle the entire burner unit (see Section 6.6.1); • Remove the gas valve (see Section 6.6.5); • Remove the condensate drainpipe; • Remove the flow and return pipe work; • Remove the support brackets and pull out the heat exchanger; • Remove the sensors and pipes from the old exchanger and fit them to the new one; • Replace the heat exchanger and reassemble the components following the above procedure in reverse order; • Switch on the electricity, water and gas supplies; • Refill the system (see Sections 5.2) and check for any leaks; • Fire the boiler and check for any flue gas leaks. TR05A140.B1107 51 MAINTENANCE INSTRUCTIONS 6.7 Wiring diagram PRINTED CIRCUIT BOARD KOND DT - SK11003 COD. 18767002 PRINTED CIRCUIT BOARD DIGITECH - SM20019 COD. 16766077 M1 M2 M3 M5 M4 M6 EXHAUST FAN type RG128/1300-3612 M7 M8 POWER SUPPLY + M9 M10 EV1 EV2 L brown black light-blue brown black CVI-M VK 4105 G fusibile 2A yellow/green N M7 Telephone control orange red brown light-blue EXTERNAL CONTROLS Key IG PA TS TF SR EV ER EA Tra C Pacq Main Switch Air Pressure switch Safety thermostat Thermofuse 102°C Heating sensor Fan Ionisation electrode Ignition electrode Ignition transformer Circulating pump Water pressure switch Remote control light-blue light-blue M5 4 M9 light-blue 10000 Ohm M1 5 Pacq orange SR Zone valve management + option remote controller board 4 3 orange TS 2 Zone valve contact closure M6 M2 7 6 5 4 3 2 1 6 5 4 3 2 1 8 7 6 5 4 3 2 1 Figure 51: Internal wiring TR05A140.B1107 remote controller zone valve light-blue 1 6 black light-blue 3 orange orange light-blue brown M10 2 5 TF IG 1 4 white/black 3 brown 2 brown 1 brown C Storage cylinder timer (option) brown SE 52 M4 MAINTENANCE INSTRUCTIONS 6.8 Troubleshooting 6.8.1 Error codes CODE E01 PROBLEM NO FLAME (FLAME FAILURE DURING STARTUP) E02 SAFETY THERMOSTAT TRIPPED (95°C) E03 FLUE THERMOFUSE TRIPPED 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. CHECK MAINS SUPPLY b. CHECK INLET PRESSURE c. CHECK AND ADJUST MECHANICAL d. IGNITION ELECTRODE BROKEN OR EARTHED e. GAS VALVE MALFUNCTION d. e. IF BOILER FIRES NORMALLY f. MAINS LIVE AND NEUTRAL WIRES REVERSED g. IONISATION ELECTRODE CABLE DISCONNECTED h. IONISATION ELECTRODE MALFUNCTION f. CORRECT MAINS WIRING g. CHECK ELECTRODE WIRING h. REPLACE PART a. THERMOSTAT CABLE DISCONNECTED b. THERMOSTAT MALFUNCTION a. CHECK THERMOSTAT WIRING b. REPLACE PART a. THERMOFUSE CABLE DISCONNECTED b. THERMOFUSE LOCK OUT (DUE TO HIGH FLUE a. CHECK THERMOSTAT WIRING b. REPLACE THERMOSFUSE, TEMPERATURE) MINIMUM AND IGNITION SEQUENCE SETTINGS REPLACE PART REPLACE PART RESTART AND CHECK APPLIANCE c. THERMOFUSE MALFUNCTION c. REPLACE PART H20 LOW SYSTEM PRESSURE a. WATER PRESSURE SWITCH CABLE DISCONNECTED b. INSUFFICIENT WATER PRESSURE IN THE SYSTEM c. WATER PRESSURE SWITCH MALFUNCTION a. CHECK SWITCH WIRING b. FILL OR TOP UP THE SYSTEM c. REPLACE PART E05 HEATING SENSOR FAULT a. SENSOR CABLE DISCONNECTED OR WET b. SENSOR MALFUNCTION OR OUT OF CALIBRATION a. CHECK SENSOR WIRING b. CHECK SENSOR RESISTANCE. E16 FAN FAULT a. BURNT FAN a. REPLACE PART E22 PARAMETER PROGRAMMING REQUEST a. LOSS OF MICROPROCESSOR MEMORY a. REPROGRAM PARAMETERS E35 IONISATION ELECTORDE FAULT a. IONISATION ELECTRODE WET, DAMP OR EARTHED b. IONISATION ELECTRODE MALFUNCTION a. CHECK COMBUSTION CHAMBER b. CLEAN PART (REPLACE IF FAULT c. IONISATION ELECTRODE CABLE MALFUNCTION d. MODULATION PCB MALFUNCTION c. REPLACE PART d. REPLACE PART E42 FAN PCB FAULT a. FAN PCB TO MOD. PCB WIRING MALFUNCTION b. FAN PCB MALFUNCTION a. REPLACE PART b. REPLACE PART (RESISTANCE VALUE 10 kOhms AT 25 °C). REMAINS AFTER CLEANING) Table 10: Appliance error codes TR05A140.B1107 REPLACE IF INCORRECT 53 MAINTENANCE INSTRUCTIONS 6.9 Parts lists 6.9.1 Main components CODE DESCRIPTION 40200069 PRIMARY EXCHANGER ISOTHERM. 4+1 3+3 25KW 12240045 PUMP RSL 15/5-3-KU-CLF6 w/OPEN C1+C3 46270044 CONDENSATE TRAP 50360067 ELECTRONIC GAS VALVE 40360068 VENTURI 20370032 FAN PX128/203 230V/50Hz - PX2030 28432074 WASHER/OR CLIPS KIT FOR MULTIPLEX 28590015 WATER PRESSURE SWITCH PC 5411 BRASS 40735016 HTG CLIP SENSOR X PIPE 17/18 mm. BLUE 40735017 THERMO FUSE 102°C RED ISTMQ 1/4" 4X45 16766077 PRINTED CIRCUIT BOARD BMBC c/DISPLAY 18767002 PRINTED CIRCUIT BOARD KOND DT 44860006 SAFETY THERMOSTAT 95C° X EL.TB 1NT 28860014 WATER PRESSURE GAUGE M3A-ABS 40 0-4 G1/8C/D+C 18880019 TRANSFORMER AC1 230VAC 25HZ 39/3200Y 48950013 EXPANSION VESSEL LT.7 3/8" 12960039 3 BAR PRESSURE RELIEF VALVE -HTG CIRCUIT Table 11: Short parts list TR05A140.B1107 54 OPTIONAL CONTROLS 7 OPTIONAL CONTROLS 7.1 External controls, programmers and room thermostats All external controls used with this appliance MUST BE ZERO-VOLT SWITCHING ONLY! If mains voltage, i.e. a switched live, is fed to the control terminals THE APPLIANCE WILL NOT FUNCTION and could be SEVERELY DAMAGED! 7.1.1 Appliance connections To fit a programmer, room thermostat or other external controls: Isolate the electricity, water and gas supplies to the appliance; Remove the front casing panel of the boiler (refer to 6.3 for guidance); • Remove terminal block cover A of the control panel; • Remove the link between the two terminals marked Ta on terminal block B; • Connect the two wires from the programmer, room thermostat or controls to the terminals marked Ta; • Replace terminal block cover A. N Ta Ta Se Se • • B L External Controls: A - Programmer - Room thermostat - S-Plan system Figure 52: Connection of external controls TR05A140.B1107 55 7.1.2 S-Plan wiring schematic Figure 53: S-Plan wiring schematic TR05A140.B1107 Heating Zone Hot Water Cylinder Room Thermostat 56 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 THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK 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 TR05A140.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) TR05A140.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 Signature Signature Service 5 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Service 6 Signature Signature Service 7 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Service 8 Signature Signature Service 9 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Service 10 Signature Signature TR05A140.B1107 Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments Date: Engineer Name Company Name Tel. No. CORGI ID Serial No. Comments 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. TR05A140.B1107