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Fault Finding

7.1

Fault Finding

Fault

Action

NO IGNITION
AT PILOT

(a)

(b)

(c)

Power to unit interrupted
Thermostat faulty

Spark ignition control module faulty

FLUE FAN RUNS NO
IGNITION SPARK

(a)

(b)

Faulty air pressure switch
Faulty spark ignition lead

FLUE FAN DOES

NOT RUN

(a)

(b)

(c)

Power to unit interrupted

Faulty fan motor

Flue fan ECO actuated

HEATER WILL NOT
LIGHT LOCKOUT

ALARM ILLUMINATED

(a)

Check gas service cock is open Press reset button Check action of flue fan ECO. If this switch is
Actuating check:

MAIN BURNER

OUTAGE AT
PERIODIC INTERVALS

(a)

(b)

(c)

(d)

Sufficient ventilation is provided

The resistance of the flue system is to high

The burner pressure is to high

The flue fan ECO is faulty

WATER

TEMPERATURE

TOO HIGH

(a)

(b)

(c)

Reset thermostat to lower temperature.

Thermostat faulty. Check and replace if necessary.

Main gas valve not closing. Clean or replace.

WATER

TEMPERATURE
TOO LOW

(a)

(b)

(c)

Reset thermostat to higher temperature.

Check gas pressures at burner and at gas inlet to heater.

Thermostat faulty. Check and replace if necessary.

NOT ENOUGH
HOT WATER

(a)

(b)

Check gas pressures at burner and at gas inlet to heater.

Check amount of water being used against recovery rate given on data plate. If usage too high,

more heating capacity needed.

WATER DRIPPING

FROM BASE OF
HEATER

(a)

(b)

Check if this stops when water in heater is hot. If yes, then condensation is the problem caused

by incorrectly designed flue or by tank cooling excessively, i.e. more hot water being used than
recovery rate of heater. If so, more heating capacity needed.

If water continues to drip when heater is hot, problem is leaking joint or storage vessel.

RUMBLING NOISE

(a)

Scale formation in heater, consult water treatment specialist. Heater must be descaled and
suitable water treatment provided to avoid re-occurrence.

Содержание 10/105

Страница 1: ...Issue 4 21 04 18 Please read and understand these instructions before commencing installation and leave this manual with the customer for future reference Andrews Builttoperform ...

Страница 2: ...ervice on Andrews Water Heaters must be carried out by properly qualified personnel and therefore no liability can be accepted for any damage or malfunction caused as a result of intervention by unauthorised personnel Andrews Water Heaters policy is one of continuous product improvement and therefore the information in this manual whilst completely up to date at the time of publication may be subj...

Страница 3: ...11 Wiring Diagram 21 4 Commissioning 22 4 1 Commissioning 22 4 2 Users Safety Guide 22 5 Operation 23 5 1 Burner Assembly 23 5 2 Burner flame check 24 5 4 Temperature selection procedure 25 6 1 Introduction 30 6 2 Burner Assembly 32 6 3 Gas Control Valve 33 6 4 Magnesium Anode 34 6 5 Descaling Information 34 6 6 Accessing service mode on the water heater display Service personnel only 35 6 7 How t...

Страница 4: ...9 Appendix 57 9 1 Dismantling Disposal and Recycling 57 Copyright 57 ...

Страница 5: ... Specification for design installation testing and maintenance of services supplying water for domestic use within buildings and their curtilages This standard supersedes the following British Standards and Codes of Practice CP99 CP310 CP324 202 CP342 Part 2 Centralised Hot Water Supply BS 5440 Installation of flues and ventilation for gas appliances of rated output not exceeding 60kW Part 1 Speci...

Страница 6: ... Safety Executive HS G70 and the Chartered Institute of Building Services Engineers CIBSE TM13 All Codes of Practice draw attention to the design and operation of water systems with reference to avoidance of factors that favour colonisation by Legionella bacteria These factors include stagnation lukewarm conditions 20 C to 45 C and the accumulation of debris scale and corrosion in the base of tank...

Страница 7: ...2 Technical Data Technical Data 2 2 1 Appliance Dimensions Fig 1 CLASSICflo 10 105 10 145 14 175 CLASSICflo 15 270 20 360 7 ...

Страница 8: ...56 9 509 3 B mm 200 200 200 262 260 4 C mm 981 1041 1267 1319 1492 D mm 1140 1222 1439 1515 1646 E mm 508 559 559 660 718 F mm 1220 1303 1540 1595 1776 G mm 762 762 762 1143 1270 H mm 102 102 102 125 125 I mm 203 203 279 279 406 J mm 305 305 305 305 305 K mm 610 610 610 610 610 L mm 340 424 435 8 ...

Страница 9: ...A Water Content Litres 105 144 175 270 360 Weight Empty kg 55 65 82 111 153 Weight Full kg 159 209 257 380 512 Shipping Weight kg 64 74 91 120 188 Storage Losses kWh l day 0 14 0 14 0 19 0 23 0 32 Inlet Outlet Connections Inch BSP 3 4 3 4 3 4 1 1 25 Return Connection Inch BSP 3 4 3 4 3 4 1 1 25 Gas Connection Inch BSP 1 2 1 2 1 2 1 2 1 2 Condensate Connection mm N A N A N A N A N A Twin Pipe Conve...

Страница 10: ... relate to enabled smart control settings CLASSICflo Natural Gas 10 105 10 145 14 175 15 270 20 360 Daily electricity consumption Qelec kWh 0 17 0 17 0 16 0 18 0 17 Declared load profile Sound power level indoors LWA dB 40 40 40 40 40 Daily fuel consumption Qfuel kWh 33 33 33 35 36 Emissions of nitrogen oxides NOx mg kW h 21 33 40 25 31 Weekly fuel consumption with smart controls Qfuel week smart ...

Страница 11: ...nstalled must be flat level and of sufficient strength to withstand the weight of the heater when filled with water and should satisfy the requirements of the Local Authority Building Regulations Any combustible material adjacent to the heater must be so placed or shielded as to ensure that its temperature does not exceed 65 C 3 3 Assembling the draught diverter The draught diverter must be assemb...

Страница 12: ... being of a type accepted by the Local Gas Authority When passing up through or adjacent to combustible materials measures shall be taken to prevent the temperature of the combustible material from exceeding 60 C The flue shall not be closer than 50mm to any combustible material except when passing through when it must be enclosed by a non combustible sleeve and separated from the sleeve by not le...

Страница 13: ...Without parapet 250mm above roof intersection Each unit has an atmospheric burner system uses natural gas Heater with highest usage fitted nearest to main flue if applicable Fig 4 Common flues may be used on multiple installations only if all the heaters are of the same burner system and fuel type and should be sized to ensure complete evacuation of the flue products from the installation Where on...

Страница 14: ...air vents must communicate with the same room or internal space or must both be on the same wall to outside air Where compartment air vents are open to a room or internal space the room or internal space must itself have a permanent air vent s as previously specified For multiple installations where the total heat input exceeds 60 kW 204 720 BTU s hr reference must be made to BS 6644 The table on ...

Страница 15: ...e event of failure of either the inlet or extract fans NB The vapours given off by halogen based compounds can if drawn into the combustion air cause corrosion of the storage vessel and premature failure of the thermocouple If water heaters are to be installed in locations where halogens are likely to be present they should be isolated from such compounds and ventilated from and to outside unconta...

Страница 16: ...odes as an alternative to the standard magnesium anodes These anodes do not need maintenance or replacement The potentiostat which regulates the current to the CorrexTM anode features an indicator light which shows green to indicate correct function and red to indicate malfunction These anodes are available as an optional extra on all Andrews heaters In hard water areas scale formation can occur i...

Страница 17: ...llowed for a feed cistern is 227 litres The actual cistern capacity is the capacity to the normal water line of the cistern All cisterns used should be to the relevant British Standard and the distance from the normal water line to the top of the cistern should be as laid down by the water authorities The cold water inlet and hot water outlet are identified on top of the heater Connect the cold wa...

Страница 18: ...ems Kit Fig 6 illustrates the general arrangement of the components The Wall Mounting Kit is available as an optional extra Items D4 D6 must be fitted into the Temperature Relief port see Fig 7 When assembling items D1 and D2 care must be taken to ensure that the flow arrows marked on the components are pointing in the direction of flow i e towards the water heater The cold water for services may ...

Страница 19: ...ist Ref Part No Description Q t 7703928 Unvented Systems Kit Complete 1 D1 7705036 Pressure Reducing Valve Check Valve Expansion Valve 1 D2 7705037 Expansion Vessel 24L 1 D3 7705038 Temperature Pressure Relief Valve 1 D4 7705039 Tundish 1 D5 7705040 Adaptor 1 D6 7705041 Hose Assembly 1 19 ...

Страница 20: ...ult your local Gas Region It is recommended that a pressure test point is fitted on the input next to the gas supply valve 3 10 Electrical Supply The method of connection to the mains electricity supply should facilitate complete electrical isolation of the appliance preferably by use of an unswitched fused spur Alternatively a fused double pole switch or fused spur box serving only the heater may...

Страница 21: ...3 11 Wiring Diagram Fig 10 21 ...

Страница 22: ...n page 28 4 Set the desired temperature by following Fig 12 to 18 on pages 26 27 5 Ensure time switch if fitted is in the on position 6 If the burner does not light an error code will be displayed on control display 4 1 2 To Shut off the Burner To shut off the burner isolate the electrical supply then shut off the gas service cock The water heater should only be turned OFF for long periods eg holi...

Страница 23: ...to allow for any unburnt gas to disperse Ventilate the area if possible Danger FOR YOUR SAFETY IF YOU SMELL GAS 1 Turn off gas supply and open windows 2 Do not operate electrical switches 3 Extinguish any naked flames 4 Contact gas supplier if the smell of gas persists FOR YOUR SAFETY Do not store or use petrol aerosol or other flammable vapours or liquids in the vicinity of this or any other atmo...

Страница 24: ...ld it become necessary to completely drain the heater close the cold water inlet valve open a hot water tap to allow air to enter the system Fit a suitable hose to the drain cock and open Whenever the Heater is filled with cold water condensation will form on the cold storage vessel surfaces when the burner is lit Condensation is normal and does not indicate a leak It will disappear when the stora...

Страница 25: ...amaged or if any joint is found not sealed 5 3 Control sequence of operation 5 3 1 Start up sequence Upon powering up the control checks for the presence of the resistive plug If the resistance is in the expected range the control will begin normal operation after 5 to 8 seconds 5 3 2 Sequence of operation 1 A call for heat from thermostat 2 Igniter warm up 3 Main burner ON 4 Flame signal confirme...

Страница 26: ... display for the definition of the error code and call your plumbing professional or service agent to service the water heater Do not try to reset the water heater without having a qualified service person to diagnose and correct the problem If the display is blank or does not show an error code make sure there is power to the water heater Setting the water temperature to the maximum setpoint can ...

Страница 27: ... To increase Setpoint temperature 1 Depress and hold Temperature Up button untildesired setpoint temperature appears in the display Fig 14 Setpoint flashes 2 Setpoint indicator begins flashing in the display after pressing Temperature Up button Fig 15 Fig 14 Fig 16 Setpoint flashes for 10 seconds Press SET button for setting to take effect immediately 3 Press SET button for new setting to take eff...

Страница 28: ...ing in the display after pressing Temperature Down button Fig 18 Fig 18 Fig 19 Setpoint flashes for 10 seconds Press SET button for setting to take effect immediately 3 Press SET button for new setting to take effectimmediately Setpoint will stop flashing If the SET button is not pressed the new temperature setting will take effect in approximately 10 seconds Fig 19 Setpoint flashes 28 ...

Страница 29: ...til F C is displayed Fig 20 Fig 20 2 Press SET button to change temperature format Symbol F C will flash Fig 21 F C flashes Fig 21 Changes to C 3a Press Temperature Up button to change temperature format to C Fig 22 Fig 22 Changes to F 3b Press Temperature Down button to change temperature format to F Fig 23 Fig 23 29 ...

Страница 30: ...operation It is recommended that all service work be performed by Andrews Water Heaters Service Team If the water heater is to remain idle for 30 days or more or is subjected to freezing temperatures while shut off the water heater and piping should be fully drained See To Drain the Water Heater and the drain valve should be left fully open Warning Hydrogen gas can be produced in an operating wate...

Страница 31: ...ealed DO NOT operate this water heater if any part is found damaged or if any joint is found not sealed The following maintenance should be performed by a qualified service technician at the minimum periodic intervals suggested below In some installations the maintenance interval may be more frequent depending on the amount of use and the operating conditions of the water heater Regular inspection...

Страница 32: ...anode rods have been installed to extend tank life These anode rods should be inspected periodically every 2 years and replaced when necessary to prolong tank life Water conditions in your area will influence the time interval for inspection and replacement of an anode rod Contact the plumbing professional who installed the water heater or the manufacturer listed on the rating plate for anode repl...

Страница 33: ...e screw securing the pilot assembly to the main burner supply tube 5 Remove the gland nut connecting the pilot tube to the pilot assembly Withdraw the pilot tube and remove the pilot restrictor from the end Clean the pilot restrictor and blow through the pilot burner with compressed air DO NOT ATTEMPT TO CLEAN ORIFICES OR MAIN BURNER SURFACE WITH SHARP METALLIC OBJECTS 6 Re assemble in the reverse...

Страница 34: ...nd remove the outer door and remove the inner door by sliding to the side of the heater 2 Disconnect burner gas tube pilot tube and blue ignition lead at gas control 3 Remove burner assembly complete with pipes and blue ignition lead 4 Disconnect electrical connection from the top of the heater Remove the screws that hold the flue fan in place and remove the flue fan 5 Withdraw the flue baffle 6 C...

Страница 35: ...e maintenance is required 6 5 Descaling Information When descaling the storage water heater your attention is drawn to the following guidelines Caution Due to the corrosive nature of descaling fluid it is essential that suitable protective clothing is used and adequate ventilation available when descaling It is important to follow descaling manufactures instructions before and during use 1 Turn ga...

Страница 36: ...elect and Temperature Up buttons togetherand hold for 3 seconds until Max Setpoint is shown in the display Fig 27 Note 30 Seconds after the last button press the display will automatically return to the User Mode Simultaneously pressing the Select and Temperature Up buttons will switch the display immediately to the User Mode Fig 27 2 Pressing Select button will change display to next mode Fig 28 ...

Страница 37: ...r Display Reset This is only shown if there is an operating error in the User Mode Fig 29 1 Max Setpoint Display Change Fig 30 Fig 30 2 Water Temperature Average Displays average if there are two sensors sensor temperature displayed if single sensor is used Fig 31 Fig 31 2b Water Temperature Upper Sensor Displays if there is an upper sensor some models Fig 32 Fig 32 idle idle idle 37 ...

Страница 38: ...there are two sensors Fig 33 Fig 33 3 Flame Current of Pilot Flame Sensor Displays only in the Heating Cycle Fig 34 Fig 34 4 Setpoint Display Change Fig 35 Fig 35 5 F C Display Change Fig 36 Fig 36 idle µA Flame Current setpoint idle F F C idle 38 ...

Страница 39: ...g 37 7 Software Version Display only Fig 38 Fig 38 No current error codes 8 Error Code History Displays if there are present error codes or up to 10 previous error codes Water Heater Display will show if there are no error codes Fig 39 Fig 39 F Differential idle Soft idle idle 39 ...

Страница 40: ... can select Note The maximum setpoint is approximately 82C Fig 42 Fig 42 Max Setpoint stops flashing 4 Press Set button to confirm new Max Setpoint value and stop setting mode Fig 43 Warning Setting the water temperature to the maximum set point can result in scalding hot water delivered to the domestic hot water outlets It is highly recommended that the maximum setpoint be adjusted to the lowest ...

Страница 41: ...g two temperature sensors in the tank this will be the average reading between the two sensors For water heaters using a single sensor this is the reading for the sensor Fig 45 Fig 45 Fig 46 2 For water heaters using two temperature sensors pressing the Select button again displays the Upper Sensor temperature reading Upper Sensor will be displayed in the lower right side of the status window of t...

Страница 42: ...e Select button until Setpoint is shown in the water heater display Fig 49 Fig 49 Setpoint flashes 2 Press the Set button to enter the setting mode Setpoint will flash in the water heater display Fig 50 Fig 50 Setpoint flashes 3 To raise the temperature setpoint press the Temperature Up button until the desired temperature is shown on the water heater display Fig 50 Note The maximum temperature th...

Страница 43: ...eached on the water heater display press the Set button to confirm the newsetpoint Setpoint stops flashing in the water heater display Fig 53 Fig 53 6 6 6 To display and change temperature format F C 1 While in Service Mode press Select button until F C is shown in the upper right portion of the water heater display Fig 54 Fig 54 2 Press Set button to change temperature format F C symbol will flas...

Страница 44: ...ress Temperature Down button to change temperature format to F Fig 57 Fig 57 4 Press Set button to confirm F or C format F C will stop flashing Fig 58 F C symbol stops flashing Fig 58 5 Pressing Select button will return display to setpoint in format selected F or C immediately Fig 59 Setpoint shown in F Fig 59 F C Flashes F 44 ...

Страница 45: ...Fig 60 The control will also go through 3 attempts to relight the burners every hour in the soft lockout condition 6 7 2 Resetting error codes in hard lockout condition All other error codes will put the water heater into a Hard Lockout condition in which the water heater will not operate and cannot be reset in the User Mode To reset a hard lockout first enter the Service Mode described earlier by...

Страница 46: ...hows there is not a current error code The Water Heater Display will provide up to 10 previous error codes The oldest error code will be stored in code index 1 and the most recent in code index 10 if there are 10 error codes 6 7 5 To view previous error codes 1 In Service Mode press the Select button until the next display after the Software Version If there are no current error codes the display ...

Страница 47: ...ss Select to view the error code number if any for that index number Continue on to index 1 the oldest error code index The water heater display will store up to 10 error codes with the oldest code starting in code index 1 with the most recent code in code index 10 Fig 68 7 10 seconds after the last button press the Water Heater Display will revert back to the current error code display To exit Se...

Страница 48: ...should be present at the gas valve before or after ignition cycle Make sure wire positions on the wire harness are correct If gas valve is stuck open replace 23 Flame detected before ignition Check to make sure gas valve has closed No voltage should be present at the gas valve before the ignition cycle Make sure wire positions on the wire harness are correct If gas valve is stuck open replace 24 F...

Страница 49: ...re on rating label Is pilot electrode sparking Check gas valve wire harness for broken wires or shorts If 24 volts is present between PV and PV MV terminals at the gas valve replace gas valve Check for voltage output to the yellow and red gas valve wires on the control board pins If during the ignition trial period there is no voltage present at the control board pin terminal for the red and yello...

Страница 50: ...heck and replace ifnecessary Main gas valve not closing Clean or replace WATER TEMPERATURE TOO LOW a b c Reset thermostat to higher temperature Check gas pressures at burner and at gas inlet to heater Thermostat faulty Check and replace if necessary NOT ENOUGH HOT WATER a b Check gas pressures at burner and at gas inlet to heater Check amount of water being used against recovery rate given on data...

Страница 51: ...8 Parts List 8 Parts List 8 1 General Assembly Fig 70 51 ...

Страница 52: ...Introduction 1 52 ...

Страница 53: ...Introduction 1 53 ...

Страница 54: ...Parts List 8 8 2 Control Box Assembly 54 ...

Страница 55: ...0 7695158 3 4 NPT Pipe Plug 1 11 7703875 Brass Sensor Well 1 12 7678973 Gas Valve Mounting Bracket 1 13 7678972 Gas Control Valve Nat Gas 1 14 7703876 Outer Door 1 15 7703877 Inner Door Gasket Kit 1 16 7703878 Burner Assembly Complete 10 105 1 16 7703879 Burner Assembly Complete 10 145 1 16 7703880 Burner Assembly Complete 14 175 1 17 Z194 Screw 18 x 1 2 HWH 1 18 7703881 Gas Pilot Assembly 1 19 77...

Страница 56: ...hermal Swich 1 26 7703903 Gas Main Burner Orifice NG 1 General Assembly 20 360 No Part No Description Qty 10 105 10 145 14 175 15 270 20 360 1 7703904 Draft Diverter Kit 20 360 1 1A 7678063 Draft Diverter Kit Legs only 1 1B 7703905 Draft Diverter Kit Diverter only 20 360 1 2 Z278 Hex Head Anode mag 1 3 7703906 Cold Feed Inlet Dip Tube 20 360 1 4 7703908 Flue Reducer 1 5 7703909 Flue Baffle 1 6 C69...

Страница 57: ...16 Screw 18 x 5 16 2 V Z264 Strain Relief Bush 1 2 1 W Z257 Snap in Bushing 7 8 2 X Z251 Power Harness 1 Y 7703917 Gas Valve Control Wiring Harness 1 Z 7703918 Damper Harness Jumper 1 Conversion Kis Nat to LPG 7697163 Conversion Kit 10 105L 1 7697164 Conversion Kit 10 145L 1 7697165 Conversion Kit 14 175L 1 7697166 Conversion Kit 15 270L 1 7697167 Conversion Kit 20 360L 1 BMS Interface 7705366 BMS...

Страница 58: ... cannot be discarded along with normal household waste and should be recycled where appropriate More than 90 of the materials that make up the appliance are recyclable Copyright All technical and technological information contained in these technical instructions as well as any drawings and technical descriptions supplied remain our property and shall not be multiplied without our prior consent in...

Страница 59: ......

Страница 60: ...ANDSERVICEMANUAL April 2018 Customer support Monday Friday 8am 5pm Sales 0345 070 1055 Technical 03450701057 Website andrewswaterheaters co uk Twitter AndrewsWH ICOM Energy Association Andrews Builttoperform www andrewswaterheaters co uk warranty ...

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