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MAINTENANCE INSTRUCTIONS

TR05A153.B1107

6.7 Maintenance operations

Before carrying out any cleaning or part replacement operations, ALWAYS turn off the ELECTRICITY,
WATER and GAS supplies to the boiler.

Warmflow will not be held responsible for damage to any of

the boiler’s components caused by non-compliance with this instruction.

Section 6.3 gives instructions on accessing the boiler, removing casing panels, and accessing the control panel.

Figure 43: Key components

Secondary heat exchanger

Ionisation electrode

Ignition electrode

DHW sensor

Circulating pump

Condensate trap

Expansion vessel

Air pressure switch

Electric fan

Primary heat exchanger

DHW heat exchanger

3-way diverter valve

Ignition transformer

Heating sensor

Safety thermostat

Gas valve

Содержание GC29B

Страница 1: ...User Instructions Installation Instructions Commissioning Instructions Maintenance Instructions Commissioning Certificate Service Record High Efficiency Condensing Gas Boilers Model covered by this ma...

Страница 2: ...TR05A153 B1107...

Страница 3: ...18 4 3 1 Compartment ventilation 18 4 4 Water connections 19 4 4 1 Domestic hot water circuit 19 4 4 2 Central heating circuit 20 4 4 3 Filling the central heating system 20 4 5 Condensate drain 21 4...

Страница 4: ...tion 50 6 3 Accessing the boiler 51 6 3 1 Front panel removal 51 6 3 2 Side panel removal 51 6 3 3 Control panel access 51 6 4 Draining the central heating system 52 6 5 Flushing the central heating s...

Страница 5: ...CONTENTS TR05A153 B1107 7 1 1 Appliance connections 66 7 1 2 S Plan wiring schematic 67 7 2 Weather compensating controls 68 7 2 1 Fitting the outside sensor 68 7 2 2 Controlling the appliance 68...

Страница 6: ...ee Section 1 1 3 below Press the MODE button 6 either the or Icons will appear on the display Adjusting the Central Heating temperature Turn the Central Heating Control knob 2 the temperature setting...

Страница 7: ...n 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 boil...

Страница 8: ...roduct 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...

Страница 9: ...ed 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 ele...

Страница 10: ...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 7...

Страница 11: ...essure bar 0 5 DHW flow rate at T 25 C litres min 16 63 DHW flow rate at T 30 C litres min 13 86 DHW flow rate at T 35 C litres min 11 89 Dimensions Width mm 450 Height mm 830 Depth mm 330 Weight net...

Страница 12: ...0 102 330 130 160 450 830 325 104 226 224 160 G HR HWO CWI HF ON OFF MODE ON OFF TIME 3 2 Dimensions LEGEND HR HEATING RETURN 22mm HF HEATING FLOW 22mm G GAS 22mm CWI COLD WATER INLET 15mm HWO HOT WAT...

Страница 13: ...S VALVE 12 PUMP WITH AIR VENT 13 AUTOMATIC AIR VENT VALVE 14 3 BAR PRESSURE RELIEF VALVE HEATING CIRCUIT 15 SYSTEM DRAIN VALVE 16 WATER PRESSURE GAUGE 17 WATER PRESSURE SWITCH 18 HEATING SENSOR 19 DHW...

Страница 14: ...VENT VALVE 14 3 BAR PRESSURE RELIEF VALVE HEATING CIRCUIT 15 SYSTEM DRAIN VALVE 16 WATER PRESSURE GAUGE 17 WATER PRESSURE SWITCH 18 HEATING SENSOR 19 DHW SENSOR 20 3 WAY VALVE 21 IGNITION TRANSFORMER...

Страница 15: ...mp performance curves I II I II III 1400 1200 1600 70 50 60 40 1000 800 400 600 30 10 20 0 0 200 III Available head at minimum speed Available head at second speed Available head at maximum speed Flow...

Страница 16: ...or Icons see Section 3 6 3 MODE button pressed Cycles through or Icons see Section 3 6 3 CH controls call for heat Primary circuit temperature in C Icon flashes whilst CH mode is active DHW tap opene...

Страница 17: ...ing 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 se...

Страница 18: ...de of Practice In the United Kingdom the following Codes of Practice apply BS 5440 Part 1 Flues BS 5440 Part 2 Air Supply BS 5546 Installation of hot water supplies for domestic purposes BS 5449 Force...

Страница 19: ...eft 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...

Страница 20: ...oiler 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 t...

Страница 21: ...ore than 17 5 Ck It is nevertheless advisable to check the properties of the water supply and install the appropriate treatment devices where necessary The cold water supply pressure at the inlet to t...

Страница 22: ...ystem bypass is fitted Lockshield valve Mains water inlet Pressure reducing valve reccomended for inlet supplies in excess pf 3 5 bar DHW outlet Filling point see fig 2 Radiator valve Note A drain tap...

Страница 23: ...garage must be insulated to protect against frost It is also recommended that the pipe diameter is increased to 32mm Any pipe run external to the building must not exceed 3 metres in length If the bo...

Страница 24: ...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...

Страница 25: ...th 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...

Страница 26: ...nt 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 function...

Страница 27: ...amber which has been specifically designed to collect and drain the acidic condensate For the air intake duct of a twin pipe system the entire length of the duct must slope downwards towards the exter...

Страница 28: ...ur 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 ter...

Страница 29: ...g 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 60 100 x 90 bend 0 8 m 60 100 x 45 bend 0 5 m If a...

Страница 30: ...The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend see below 60 100 x 90 bend 0 8 m 60 100 x 45 bend 0 5 m If a flue length of a...

Страница 31: ...length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend see below 60 100 x 90 bend 0 8 m 680 100 x 45 bend 0 5 m If a flue length of above 4 me...

Страница 32: ...length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend see below 60 100 x 90 bend 0 8 m 680 100 x 45 bend 0 5 m If a flue length of above 5 met...

Страница 33: ...and nut provided with the flue kit Push the flared end of the 60 aluminium collar over the plastic inner pipe of the flue starter elbow ensuring a snug fit Mount the flue starter assembly onto the boi...

Страница 34: ...UM FLUE LENGTH 4 m COAXIAL BALANCED FLUES 60 100 Horizontal Kit K and Vertical Kit V Figure 27 60 100 Balanced flue diaphragm settings 3 INDICATOR 5 2 1 4 FOR ADJUSTMENT DISC LOWER DISC UPPER NUMBERS...

Страница 35: ...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 80 x 9...

Страница 36: ...starter piece to the boiler passing the screws provided with the flue kit through the flange and gasket then screwing them into the flue spigot Place the lower diaphragm with the numbered scale onto...

Страница 37: ...R 3 LOWER DISK TOTAL EQUIVALENT FLUE LENGTH DIAPHRAGM SETTING from 0 to 10 m including inlet exhaust sections 1 2 3 from 10 to 30 m including inlet exhaust sections 1 2 3 from 30 to 40 m including inl...

Страница 38: ...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 i...

Страница 39: ...y see Section 3 6 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 disp...

Страница 40: ...Control Panel see Section 3 6 After a few seconds the circulating pump will start to run Ensure that the boiler controls time clock and any system controls are calling for heat The automatic ignition...

Страница 41: ...pressure gauge to the meter outlet sampling point Reopen the meter isolation valve and operate the appliance at maximum gas rate as described above The pressure gauge will now measure the working pres...

Страница 42: ...ng a screw driver Switch the appliance off before disconnecting the pressure gauge 5 6 3 Mechanical maximum gas pressure The maximum gas pressure for this appliance has been factory set Nonetheless it...

Страница 43: ...5 7 2 at which point the boiler will fire Referring to the Heating Output vs Parameter Value curves in Figure 38 adjust the value of Parameter 11 to the desired output Complete the Parameter adjustmen...

Страница 44: ...sec 7 CH pump overrun timer 00 90 default 36 Expressed in steps of 5 seconds Default 36 x 5 sec 180 sec 8 DHW pump overrun timer 00 90 default 18 Expressed in steps of 5 seconds Default 18 x 5 sec 90...

Страница 45: ...tch the appliance on using the ON OFF button Release the buttons Step 3 Press and hold the S button Use the button to cycle up through the parameters Step 4 Release the S button Press and release the...

Страница 46: ...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...

Страница 47: ...5 7 1 Use the buttons to adjust the parameter value 00 Off 01 On Press and release the S button The parameter number 5 will appear on the display To store your changes switch the appliance off then on...

Страница 48: ...st the parameter value 00 0 x 5 seconds 0 seconds minimum 90 90 x 5 seconds 450 seconds maximum Note Factory preset to 18 90 seconds Press and release the S button The parameter number 8 will appear o...

Страница 49: ...The parameter number 11 will appear on the display To store your changes switch the appliance off then on again using the ON OFF button Parameter 12 Ignition sequence gas pressure Refer to Section 5...

Страница 50: ...Butane Gas G30 Liquid Propane Gas G31 Lower Wobbe index 15 C 1013 mbar MJ Nm 3 45 67 80 58 70 69 Nominal Supply Pressure mbar 20 30 37 Consumption 15 C 1013 mbar m 3 h 3 17 Consumption 15 C 1013 mbar...

Страница 51: ...rner manifold item 6 from the burner ramps item 7 by undoing the 4 screws item 11 Fit new jets item 8 suitable for the new gas type to the burner using a 7mm spanner and fitting with new gaskets Reass...

Страница 52: ...nd positioned correctly The condition of the primary heat exchanger clean if necessary The maximum and minimum gas pressures and the modulation process adjust if necessary The condition and operation...

Страница 53: ...ls 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...

Страница 54: ...d close the radiator air vents and the boiler drain valve If ONLY THE BOILER needs to be drained Switch on the boiler select Heating Only Mode and allow the boiler to fire Refer to Section 3 6 for how...

Страница 55: ...mponents caused by non compliance with this instruction Section 6 3 gives instructions on accessing the boiler removing casing panels and accessing the control panel Figure 43 Key components Secondary...

Страница 56: ...ck that all burner jets are clean unobstructed and undamaged Clean the ignition and ionisation electrodes carefully and without altering their position with respect to the burner Check that the igniti...

Страница 57: ...er Refill the system see Section 5 2 and check for any leaks from the joints 6 7 3 Ignition and ionisation electrodes Isolate the electricity water and gas supplies to the appliance Unplug the electro...

Страница 58: ...electricity water and gas supplies to the appliance Disconnect and remove the pipe connecting the gas valve to the burner Disconnect the gas feed pipe Remove the screws securing the gas valve then re...

Страница 59: ...dness of the joint by measuring the CO2 levels 6 7 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 Un...

Страница 60: ...he fixing screws securing the transparent cover of the diverter valve and remove the cover Unscrew the two motor fixing screws and disconnect the wires Replace the motor and reassemble the components...

Страница 61: ...s remove the control knobs from the front of the panel unscrew the fixing screws and remove the PCB Replace the PCB and reassemble the components following the above procedure in reverse order Switch...

Страница 62: ...ry heat exchanger support bracket then remove the bracket Remove the secondary heat exchanger by pulling it to the left taking care not to snag the fan wiring Replace the heat exchanger and reassemble...

Страница 63: ...ue black orange remote controller zone valve Zone valve management option remote controller board Storage cylinder timer option blue blue PRINTED CIRCUIT BOARD DIGITECH SM20019 COD 16766077 Key IG ON...

Страница 64: ...RMOSTAT CABLE DISCONNECTED b THERMOSTAT MALFUNCTION a CHECK THERMOSTAT WIRING b REPLACE PART H20 LOW SYSTEM PRESSURE a INSUFFICIENT WATER PRESSURE IN THE SYSTEM b WATER PRESSURE SWITCH CABLE DISCONNEC...

Страница 65: ...IPLEX 40580025 HEAT EXCHANGER 32590012 AIR PRESSURE SWITCH 40580022 RECUPERATOR 28 32Kw X155 Y188 28590015 WATER PRESSURE SWITCH PC 5411 OTTONE 28735007 DHW HEATING SENSOR 1 8 WHITE 40735016 HTG CLIP...

Страница 66: ...61037 28590015 28431059 28200047 28431039 28431050 28431039 28431050 28610004 28960032 28330030 28735007 28641024 28891034 28540032 28432048 28432076 28641023 28640075 28540023 28641006 28431051 28261...

Страница 67: ...ING CLIP STAINLESS STEEL 28590015 WATER PRESSURE SWITCH PC 5411 BRASS 28610004 FLOWSWITCH PISTON 28640066 FLOWSWITCH CAP MULTIPLEX 28640068 3 WAY VALVE UPPER SECTION FOR ISTANTANEOUS MODELS 28640075 B...

Страница 68: ...m 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 cove...

Страница 69: ...tic Zero volt Switching Circuit Add more valves programmers as required Permanent Live Boiler Terminal Block Heating Zone Hot Water Cylinder Cylinder Thermostat Room Thermostat 2 port zone valves Zone...

Страница 70: ...ct the two wires of the sensor to the connections marked Se on terminal block B see Figure 59 Replace terminal block cover A External Controls Room thermostat Programmer A S Plan system Se Se Ta N L B...

Страница 71: ...9 24 25 23 21 22 20 16 18 17 15 14 Tm MAX 40 80 75 12 10 12 11 8 9 7 5 6 4 2 3 1 6 3 1 0 2 4 5 9 7 8 10 11 8 9 7 6 5 0 15 13 14 1 2 3 4 Figure 60 Weather compensating control profiles Outside Temperat...

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Страница 73: ...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 Pr...

Страница 74: ...mum Burner Operating Pressure mbar Maximum Operating Water Pressure bar Cold Water Inlet Temperature C Hot Water Outlet Temperature C Water Flow Rate at Maximum Setting l min For Condensing Boilers On...

Страница 75: ...No Comments Comments Signature Signature Service 5 Date Service 6 Date Engineer Name Engineer Name Company Name Company Name Tel No Tel No CORGI ID Serial No CORGI ID Serial No Comments Comments Sign...

Страница 76: ...THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK...

Страница 77: ...THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK...

Страница 78: ...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 PRIN...

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