Glow-worm ENERGY 12r -A (H-GB), 15r -A (H-GB), 18r -A (H-GB), 25r -A (H-GB), 30r -A (H-GB) water heaters & boilers Installation and maintenance instructions

The energy you need

Installation and maintenance instructions

ENERGY ..r

ENERGY 12r -A (H-GB)





GB

Contents

6

6.1

6.2

6.3

7

5.3

5.4

5.5

5.6

7.1

7.2

7.3

7.4

2.1

2.2

2.3

3

3.1

3.2

1

1.1

1.2

1.3

1.4

2

3.3

3.4

4

4.1

4.2

4.9

4.10

5

5.1

5.2

4.3

4.4

4.5

4.6

4.7

4.8

Contents

7.5

7.6

7.7

7.8

7.9

Safety .................................................................... 3

Action-related warnings ......................................... 3

Intended use ......................................................... 3

General safety information .................................... 3

Regulations (directives, laws, standards) .............. 5

Notes on the documentation .............................. 7

Observing other applicable documents ................. 7

Storing documents................................................. 7

Applicability of the instructions .............................. 7

Product description............................................. 7

Serial number ........................................................ 7

Information on the identification plate.................... 7

CE label ................................................................. 7

Functional elements............................................... 8

Installation............................................................ 8

Transporting the unit.............................................. 8

Unpacking the product........................................... 8

Checking the scope of delivery.............................. 8

Dimensions ............................................................ 9

Minimum clearances.............................................. 9

Clearance from combustible components ............. 9

Using the installation template............................... 9

Wall-mounting the product..................................... 9

Removing/installing the front casing.................... 10

Removing/installing the side section ................... 10

Installation.......................................................... 11

Preparing for installation...................................... 11

Connecting the heating flow and heating return ................................................................... 11

Gas connection.................................................... 11

Connecting the condensate drain pipework ........ 12

Installing the air/flue pipe..................................... 12

Electrical installation ............................................ 13

Operation............................................................ 15

Using diagnostics codes...................................... 15

Displaying the status codes................................. 15

Using check programmes.................................... 16

Start-up ............................................................... 16

Carrying out the initial start-up............................. 16

Checking the type of gas ..................................... 16

Checking the factory setting ................................ 16

Checking and treating the heating water/filling and supplementary water .................................... 16

Filling the condensate siphon .............................. 17

Switching on the product ..................................... 17

Checking the gas connection pressure (gas flow pressure) ...................................................... 18

Checking the CO₂ content ................................... 18

Setting the CO₂ content ....................................... 18

7.10

7.11

7.12

8

8.1

9

10

10.1

10.2

10.3

10.4

10.5

10.6

10.7

10.8

Checking the leak-tightness of the flue gas system and for flue gas recirculation ................... 19

Checking function and leak-tightness.................. 19

Checking the heating mode................................. 19

Adapting the unit to the heating installation.......................................................... 19

Burner anti-cycling time ....................................... 19

Handing the product over to the operator ...... 19

Inspection and maintenance ............................ 19

Observing inspection and maintenance intervals ............................................................... 19

Procuring spare parts .......................................... 19

Removing the gas-air mixture unit....................... 20

Cleaning the heat exchanger............................... 20

Checking the burner ............................................ 21

Checking the ignition electrode ........................... 21

Cleaning the condensate siphon ......................... 21

Installing the gas-air mixture unit......................... 21

10.9

Draining the product ............................................ 21

10.10

Completing inspection and maintenance work .... 21

11 Troubleshooting ................................................ 21

11.1

11.2

11.3

11.4

11.5

11.6

Rectifying faults ................................................... 21

Calling up the fault memory................................. 21

Deleting the fault memory.................................... 21

Preparing the repair work .................................... 22

Replacing defective components......................... 22

Completing repair work........................................ 23

B

C

D

E

F

12

13

Decommissioning the product......................... 23

Customer service............................................... 23

Appendix ............................................................................ 24

A

Inspection and maintenance work –

Overview............................................................. 24

Check programmes – Overview ....................... 24

Overview of diagnostics codes........................ 25

Status codes – Overview .................................. 28

Overview of fault codes .................................... 29

Connection diagram .......................................... 31

G

H

H.1

H.2

H.3

Connection diagram, 30 kW.............................. 32

Opening in the flue pipe.................................... 33

Positioning of the opening of a fan-supported flue gas pipe ........................................................ 33

Text from BS 5440-1 on fan-supported flue gas pipes ............................................................. 34

Opening of the flue pipe below eaves and balconies.............................................................. 34

I

J

Commissioning Checklist................................. 35

Combustion chart .............................................. 38

K Technical data.................................................... 39

Index ................................................................................... 43

2

Installation and maintenance instructions ENERGY ..r 0020177748_00

Safety 1

1 Safety

1.1

Action-related warnings

Classification of action-related warnings

The action-related warnings are classified in accordance with the severity of the possible danger using the following warning signs and signal words:

Warning symbols and signal words

Danger!

Imminent danger to life or risk of severe personal injury

Danger!

Risk of death from electric shock

Warning.

Risk of minor personal injury

Caution.

Risk of material or environmental damage

1.2

Intended use

There is a risk of injury or death to the user or others, or of damage to the product and other property in the event of improper use or use for which it is not intended.

The product is intended as a heat generator for closed heating installations and for hot water generation.

The products referred to in these instructions must only be installed and operated in conjunction with the flue pipe accessories listed in other applicable documents.

Exceptions: For C63 and B23P installation types, follow the specifications in these instructions.

Intended use includes the following:

– observance of accompanying operating, installation and servicing instructions for the product and any other system components

– installing and fitting the product in accordance with the product and system approval

– compliance with all inspection and maintenance conditions listed in the instructions.

Intended use also covers installation in accordance with the IP class.

Any other use that is not specified in these instructions, or use beyond that specified in this document shall be considered improper use. Any direct commercial or industrial use is also deemed to be improper.

Caution.

Improper use of any kind is prohibited.

1.3

General safety information

1.3.1 Required personnel qualifications

Improper work carried out on the product may cause material damage to the complete installation and, as a consequence, may even cause personal injury.

▶ You should therefore only work on the product if you are an authorised competent person.

▶ Carry out all work using the technology currently available.

1.3.2 Risk of injury during transport due to a high product weight.

▶ Make sure that the product is transported by at least two people.

1.3.3 Risk of death from escaping gas

What to do if you smell gas in the building:

▶ Avoid rooms that smell of gas.

▶ If possible, open doors and windows fully and ensure adequate ventilation.

▶ Do not use naked flames (e.g. lighters, matches).

▶ Do not smoke.

▶ Do not use any electrical switches, mains plugs, doorbells, telephones or other communication systems in the building.

▶ If it is safe to do so, close the emergency control valve or the main isolator.

▶ If possible, close the gas isolator cock on the product.

▶ Warn other occupants in the building by yelling or banging on doors or walls.

▶ Leave the building immediately and ensure that others do not enter the building.

▶ Notify the gas supply company or National

Grid Transco +44 (0) 800 111999 by telephone from outside of the building.

0020177748_00 ENERGY ..r Installation and maintenance instructions

3

1 Safety

1.3.4 Risk of death from escaping flue gas

If you operate the product with an empty condensate siphon, flue gas may escape into the room air.

▶ In order to operate the product, ensure that the condensate siphon is always full.

1.3.5 Risk of death due to blocked or leaking flue gas routes

Installation errors, damage, tampering, unauthorised installation sites or similar can cause flue gas to escape and result in a risk of poisoning.

What to do if you smell flue gas in the property:

▶ Open all accessible doors and windows fully to provide ventilation.

▶ Switch off the product.

▶ Check the flue gas routes in the product and the flue gas diversions.

1.3.6 Risk of poisoning and burns caused by escaping hot flue gases

▶ Only operate the product if the air/flue pipe has been completely installed.

▶ With the exception of short periods for testing purposes, only operate the product when the front casing is installed and closed.

1.3.7 Risk of death due to explosive and flammable materials

▶ Do not use or store explosive or flammable materials (e.g. petrol, paper, paint) in the installation room of the product.

1.3.8 Risk of death from electric shock

There is a risk of death from electric shock if you touch live components.

Before commencing work on the product:

▶ Disconnect the product from the power supply by switching off all power supplies

(electrical partition with a contact opening of at least 3 mm, e.g. fuse or line protection switch).

▶ Secure against being switched back on again.

▶ Wait for at least 3 minutes until the condensers have discharged.

▶ Check that there is no voltage.

1.3.9 Risk of death due to lack of safety devices

The schematic drawings included in this document do not show all safety devices required for correct installation.

▶ Install the necessary safety devices in the system.

▶ Observe the applicable national and international laws, standards and guidelines.

1.3.10 Risk of poisoning caused by insufficient supply of combustion air

Conditions: Open-flued operation

▶ Ensure that the air supply to the product's installation room is permanently unobstructed and sufficient in accordance with the relevant ventilation requirements.

1.3.11 Risk of death due to cabinet-type casing

Cabinet-type casing can give rise to dangerous situations when used on a product which is operated with an open flue.

▶ Ensure that the product is supplied with sufficient combustion air.

1.3.12 Risk of corrosion damage due to unsuitable combustion and room air

Sprays, solvents, chlorinated cleaning agents, paint, adhesives, ammonia compounds, dust or similar substances may lead to corrosion on the product and in the air/flue pipe.

▶ Ensure that the supply of combustion air is always free of fluorine, chlorine, sulphur, dust, etc.

▶ Ensure that no chemical substances are stored at the installation site.

▶ Ensure that the combustion air is not routed through chimneys which have previously been used with floor-standing oil-fired boilers, or with other boilers,

4


Safety 1

which could cause soot to build up in the chimney.

▶ If you are installing the product in hairdressing salons, painter's or joiner's workshops, cleaning businesses or similar locations, choose a separate installation room in which a combustion air supply is ensured that is technically free of chemical substances.

1.3.13 Risk of material damage caused by frost

▶ Do not install the product in rooms prone to frost.

1.3.14 Risk of being burned or scalded by hot components

▶ Only carry out work on these components once they have cooled down.

1.3.15 Risk of material damage caused by using an unsuitable tool

▶ Use the correct tool to tighten or loosen screw connections.

1.4

Regulations (directives, laws, standards)

Installation and maintenance of the boiler must only be performed by a competent person with valid accreditation from the Health and Safety Executive in accordance with the

"Gas Safety (Installation and Use) Regulations 1998" (hereinafter abbreviated to "competent person" or "heating specialist company"). The existing regulations, rules and guidelines must be observed when doing so.

Any special requirements of Local Authorities, gas undertakings or insurers must be complied with. The competent person is also responsible for inspection, maintenance and repairs to the boiler, and for checking gas volume setting and flue gas analysis.

Installers shall carryout a full site risk assessment and put into place all necessary steps and procedures to comply with Health and safety at work act and ensure safety of themselves and others with regard to manual handling and working at height requirements.

During the appliance installation (and any subsequent work, such as, the replacement of major parts ) it will be necessary to employ caution. All installers and operatives involved from unloading the appliance until it is fully mounted on the wall in its final installed location must exercise full duty of care for themselves and others with regard to safety.

When lifting and handling this appliance, operatives should employ assistance. In certain situations it may be necessary to use mechanical handling aids. Take care to avoid trip hazards, slippery or wet surfaces.

Employers and installers should refer to the HSE web site for full advice and manual handling assessment charts

(MAC) tool.

In addition where no specific instructions are given then reference shall be made, but not restricted to, all applicable and relevant British Standards and codes of practice such as the following:

– Gas Safety (Installation and Use) regulations.

– All current Building Regulations for England, Northern Ireland and Wales, (as amended). This includes Approved Codes of Practice and approved documents and guidance for building regulations. (A to P and 7)

– The Building Standards, Scotland, and any requirements determined by the local authorities within.

– The Health and safety at work act

– COSHH Control of Substances Hazardous to Health.

– BS 7671 Requirements for electrical installations. IEE Wiring Regulations

– The Electricity at Work Regulations.

– The Water supply (water fittings) regulations 1999.

– Water bylaws 2000 (Scotland)

– BS 5854 Code of practice for flues and flue structures in buildings.

– BS EN 12828 Design of water-based heating systems.

– BS EN 806 Parts 1 - 5.

– BS 8558 Guide to the design, installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages.


5

1 Safety

– BS 6880 Code of practice for low temperature heating systems with outputs above

45 kW, Part 1, 2, and 3.

– BS 6891 Installation of low pressure gas pipe work of up to 35mm in domestic premises.

– BS 4814 Specification for: Expansion vessels using an internal diaphragm, for sealed hot water and heating systems.

– BS 7074 Application, selection and installation of expansion vessels and ancillary equipment for sealed water systems., Part

1 and 2.

– BS 7593 Code of practice for treatment of water in domestic hot water central heating systems.

– BS 12831 Heating systems in buildings.

Method for calculating design heat load.

– BS EN 13831 Closed expansion vessels with built in diaphragm.

– EN 14336 Heating systems in buildings.

Installation and commissioning of water based heating systems.

– BS 5440 – 1 Installation of flues and ventilation for gas appliances of rated input not exceeding 70kW*

– BS 5440 – 2 Flueing and ventilation for gas appliances of rated input not exceeding

70kW*

* 1st 2nd and 3rd family gases.

– BS 5449 Forced circulation hot water systems up to 45kW.

– BS EN 6798 Installation & maintenance of gas fired hot water boilers of rated input not exceeding 70kW net.

– BS 5482 - Part 1 Domestic butane and propane gas burning installations

Institute of Gas Engineers Publications:

– IGE/UP/1B (Edition 2) Tightness testing and direct purging of small natural gas installations.

– IGE/UP/ 7 (Edition 2) Gas in timber and light steel framed buildings.

Additionally for gas boilers systems with outputs greater than 70KW.

– BS 6644 Installation of gas boilers between 60 kW and 2 MW (2nd and 3rd family gases)

– BS 5449

– IGE/UP/1 (Edition 2) Strength testing, tightness testing and direct purging of industrial and commercial gas installations.

– IGE/UP/1A (Edition 2) Strength testing, tightness testing and direct purging of small, low pressure industrial and commercial natural gas installations.

– IGE/UP/10 Installation of gas appliances in industrial and commercial premises.

Part 1 Flued appliances.

– The installation must comply with the current version of the Clean Air Act.

– I.S. 813 Domestic Gas Installations

– I.S. 820 Non Domestic Gas Installations

– Building Control Act 2007

– ETCI Regulations for installing electrical systems

6


Notes on the documentation 2

2

2.1

Notes on the documentation

Observing other applicable documents

▶

You must observe all the operating and installation instructions included with the system components.

2.2

Storing documents

▶

Pass these instructions and all other applicable documents on to the system operator.

2.3

Applicability of the instructions

These instructions apply only to:

Product article number

Article number Gas Council

Number

ENERGY 12r -A (H-GB)

0010015660 41-019-21


0010015661


0010015662

41-019-22

41-019-23


0010015663


0010015664

41-019-24

41-019-25

Information on the identification plate

PMW

Meaning

V/Hz

W

IP

Pn

Pnc

P

Qn

Qnw

T max.

NOx

Code (DSN)

Maximum water pressure in hot water handling mode

Electric connection

Max. electrical power consumption

Level of protection

Heating mode

Nominal heat output range in heating mode

Nominal heat output range in heating mode (condensing technology)

Nominal heat output range in hot water handling mode

Nominal heating load range in heating mode

Nominal heating load range in hot water handling mode

Max. flow temperature

NOx class for the product

Specific product code

→ "CE label" section

3 Product description

3.1

Serial number

The serial number is located on a plate behind the front flap.

The plate is in a plastic fish plate. You can also display the serial number in the display.

3.2


The identification plate is mounted on the underside of the product in the factory.

The identification plate keeps record of the country in which the product is to be installed.


Meaning

Barcode with serial number

GC no.

3.3

CE label

Read the instructions.

→ "Recycling and disposal" section

Gas council number

The CE label shows that the products comply with the basic requirements of the applicable directives as stated on the identification plate.

The declaration of conformity can be viewed at the manufacturer's site.

Serial number

ENERGY ..r

2H, G20 - 20 mbar

(2 kPa)

Cat.

Condensing technology

Type: Xx3(x)

PMS

For quality control purposes; 3rd and 4th digits = year of production

For quality control purposes; 5th and 6th digits = week of production

For identification purposes; 7th to 16th digits = product article number

For quality control purposes; 17th to 20th digits = place of manufacture

Product description

Factory setting for type of gas and gas connection pressure

Approved gas category

Efficiency class of the boiler in accordance with EC Directive 92/42/EEC

Permissible flue gas connections

Maximum water pressure in heating mode


7

4 Installation

3.4

Functional elements

4

5

6

7

8

1

2

3

9

▶

Lift the box using the straps provided.

▶

Use safe lifting techniques – keep your back straight and bend your legs at the knee.

▶

Hold the load as close as possible to your body.

▶

If the unit is being lifted by two persons, ensure your movements are coordinated during lifting.

▶

If required, get somebody to assist you in this.

4.2

Unpacking the product

1.

Remove the product from its box.

2.

Remove the protective film from all of the product's components.

4.3

Checking the scope of delivery

▶

Check that the scope of delivery is complete and intact.

4.3.1

Scope of delivery

1

1

1

1

1

1

1

Number

Description

Heat generator

Hanging bracket

Gas isolator cock

Gas pipe

Condensate drain hose

Installation template

Enclosed documentation

1

2

3

4

5

Gas-air mixture unit

Flue pipe

Flue gas analysis point

Gas valve

Ignition transformer

6

7

8

9

Heat exchanger

Air intake pipe

Condensate siphon

Electronics box

4 Installation

4.1

Transporting the unit

Important: With regard to the regulations of 1992 concerning the manual handling of loads, the unit exceeds the weight that can be lifted by a single person.

4.1.1

General

▶

Hold the load as close as possible to your body. Avoid rotational movements. Instead, reposition your feet.

▶

If the unit is being lifted by two persons, ensure your movements are coordinated during lifting.

▶

Avoid bending your upper body – do not lean forwards or to the side.

▶

Wear suitable non-slip protective gloves in order to protect your hands against sharp edges. Ensure that you are carrying the load securely.

▶

If required, get somebody to assist you in this.

4.1.2

Unloading the box from the delivery van

▶

It is recommended that two people lift the unit together.

8


4.5

Minimum clearances

Installation 4

4.4

Dimensions

1

2

C C D

33,5

183,5

375

71

78

157,5

3

4

220

5

6

1

2

3

4

Condensate discharge

Gas connection

Heating return

Heating flow

5

6

Connection on the back of the air/flue pipe

Connection on the top of the air/flue pipe

Minimum clearance

C

D

A

B

150 mm

150 mm

5 mm

600 mm

4.6

Clearance from combustible components

It is not necessary to maintain a clearance between the product and components made of combustible materials.

4.7

Using the installation template

▶

Use the installation template to ascertain the locations at which you need to drill holes and make breakthroughs.

4.8

Wall-mounting the product

Note

If you are using the rear air/flue gas connection, install the flue pipe before you wall-mount the product.

A

B


1.

Check whether the wall has sufficient load-bearing capacity to bear the operational weight of the product.

2.

Check if the supplied fixing material may be used for the wall.

9

4 Installation

Conditions: The load-bearing capacity of the wall is sufficient, The fixing material may be used for the wall

▶

Wall-mount the product as described.

Conditions: The load-bearing capacity of the wall is not sufficient

▶

Ensure that wall-mounting apparatus on-site has a sufficient load-bearing capacity. Use individual stands or primary walling, for example.

▶

Do not wall-mount the product if you cannot provide wall-mounting apparatus with a sufficient load-bearing capacity.

Conditions: The fixing material may not be used for the wall

▶

Wall-mount the product as described using the permitted fixing material provided on-site.

4.10

Removing/installing the side section

4.10.1 Removing the side section

Caution.

Risk of material damage caused by mechanical deformation.

Removing both side sections may cause mechanical distortion in the product, which may cause damage to the piping, for example, and potentially result in leaks.

▶

Always remove only one side section – never both side sections at the same time.

4.9

Removing/installing the front casing

4.9.1

Removing the front casing

Note

If there is sufficient lateral clearance (at least

70 mm), you can remove the side section to facilitate maintenance or repair work.

D

D

E

B

A

A

C

1.

Undo the two screws (1).

2.

Gently press the front casing backwards in the centre and pull it downwards on the lower edge so that the retaining clip is released.

3.

Pull the front casing forwards at the bottom edge.

4.

Lift the front casing upwards from the retainers.

4.9.2

Installing the front casing

1.

Place the front casing on the upper retainer.

2.

Press the front casing onto the product so that the retainer bracket clicks into place.

3.

Secure the front casing by tightening both screws.

C

B

1.

Tilt the electronics box forward.

2.

Hold on to the side section so that it cannot fall, and unscrew both screws, one from the top and one from the bottom.

3.

Tilt the side section to the outside and take it out towards the top.

4.10.2 Installing the side section

1.

Push the side section into the recesses in the back wall.

2.

Tilt the side section towards the product.

3.

Screw the two screws into the side section, one at the top and one at the bottom.

4.

Fold up the electronics box.

10


5 Installation

5.1

Preparing for installation

Danger!

Risk of scalding and/or damage due to incorrect installation leading to escaping water.

Stresses in the supply line can cause leaks.

▶

Make sure there is no voltage in the supply lines when they are installed.

5.2

Installation 5

Connecting the heating flow and heating return

1

2

Caution.

Risk of damage caused by corrosion.

If non-diffusion-tight plastic pipes are used in the heating installation, this may cause air to enter the heating water and corrosion of the heat generation circuit and the boiler.

▶

If using non-diffusion-tight plastic pipes in the heating installation, separate the system by installing an external heat exchanger between the boiler and the heating installation.

1 Heating return connection

2 Heating flow connection

1.

Establish the heating connections in accordance with the applicable standards.

2.

Purge the gas line before start-up.

3.

Check whether the connections (→ Page 19) are leaktight.

5.3

Gas connection

Caution.

Risk of material damage due to heat transfer during soldering.

▶

Do not solder the connection pieces if the connection pieces are screwed to the service valves.

1

Caution.

Risk of damage caused by incorrect gas installation.

Excess test pressure or operating pressure may cause damage to the gas valve.

▶

Check the leak-tightness of the gas valve using a maximum pressure of 1.1 kPa

(110 mbar).

▶

Flush the heating installation thoroughly prior to installation.

▶

Make sure that the existing gas meter is capable of passing the rate of gas supply required.

▶

Install the following components:

– Drain cocks at the lowest points of the heating installation

– A heating pump in the heating flow

– A bypass that is at least 1.5 m away from the product

– A stop cock in the gas line

1.

Establish the gas connection (1) in accordance with the applicable standards.

2.

Purge the gas line before start-up.

3.

Check whether the connections (→ Page 19) are leaktight.


11

5 Installation

5.4

Connecting the condensate drain pipework 5.5

1

2

Installing the air/flue pipe

Caution.

Risk of poisoning due to escaping flue gas.

Mineral-oil-based greases can damage the seals.

▶

Instead of grease, use only water or commercially available soft soap to aid installation.

1.

You can find out which air/flue pipes may be used by consulting the enclosed air/flue pipe installation manual.

2.

Install the flue gas pipe in accordance with the installation instructions that are included in the scope of delivery for the air/flue pipe.

5.5.1

Air/flue gas system

5.5.1.1 Horizontal air/flue gas system

▶

Follow the instructions listed here and observe directives and local regulations on condensate discharge.

▶

Use PVC or another material that is suitable for draining the non-neutralised condensate.

▶

If it cannot be guaranteed that the materials the drain lines are made from are suitable, install a system for neutralising the condensate.

▶

Ensure that the connection between the condensate drain pipework and the drain hose is not air-tight.

L

Note

The condensate drain pipework must have a continuous fall (45 mm per metre) and should whenever possible terminate at a suitable drain point within the heated envelope of the building that will remain frost free under long periods of low external temperatures.

▶

During installation remove all burs from inside of cut pipe work and avoid excessive adhesive which may trap small pockets of water close to the pipe wall which can freeze and build into a larger ice plug.

▶

As with other pipe work insulate the condensate discharge pipe to minimise any risk of freezing and beware when crossing cavities that the fall is maintained and the pipe sleeved.

You can find further information in BS 6789: "Specification for installing and maintaining gas-fired boilers with a nominal heat loading less than 70 kW".

The openings in an attachment for separate lines must lead to a 50 cm-sided square.

For each additional 90° elbow (or two 45° elbows) that is required, the length (L) must be reduced by 1 m.

Length of the C13 type flue pipe

Diameter of the air/flue pipe

ENERGY 12r -A

(H-GB)

ENERGY 15r -A

(H-GB)

ENERGY 18r -A

(H-GB)

ENERGY 25r -A

(H-GB)

ENERGY 30r -A

(H-GB)

Dia. 60/100 (L)

C13 type air/flue pipe

≤ 10 m

≤ 10 m

≤ 10 m

≤ 10 m

≤ 10 m

Dia. 80/125 (L)


≤ 25 m

≤ 25 m

≤ 25 m

≤ 25 m

≤ 19 m

12


Installation 5

5.5.1.3 Air/flue gas system for header lines 5.5.1.2 Vertical air/flue gas system

L

L

The openings in an attachment for separate lines must lead to a 50 cm-sided square.




Dia. 60/100 (L) Dia. 80/125 (L)


≤ 10 m


≤ 25 m

ENERGY 12r -A

(H-GB)

ENERGY 15r -A

(H-GB)

ENERGY 18r -A

(H-GB)

ENERGY 25r -A

(H-GB)

ENERGY 30r -A

(H-GB)

≤ 10 m

≤ 10 m

≤ 10 m

≤ 10 m

≤ 25 m

≤ 25 m

≤ 25 m

≤ 19 m

The connections with the line are established using the accessory specially developed by the product manufacturer.

A boiler that is connected to a type C43 system must only be connected to natural draught chimneys.

The condensate from header line systems must not drain into the boiler.




Dia. 60/100 (L) Dia. 80/125 (L)


≤ 10 m


≤ 10 m

ENERGY 12r -A

(H-GB)

ENERGY 15r -A

(H-GB)

ENERGY 18r -A

(H-GB)

ENERGY 25r -A

(H-GB)

ENERGY 30r -A

(H-GB)

≤ 10 m

≤ 10 m

≤ 10 m

≤ 10 m

≤ 10 m

≤ 10 m

≤ 10 m

≤ 10 m

5.6

Electrical installation

Danger!

Risk of death from electric shock!

The mains connection terminals L and N remain live even if the product is switched off:

▶

Switch off the power supply.

▶

Secure the power supply against being switched on again.


13

5 Installation

5.6.1

Opening the electronics box

A

5.6.4

Establishing the power supply

1

B

B

▶

Follow the instructions in the specified sequence.

5.6.2

Cable route

230V

1.

Observe all valid regulations.

2.

Ensure that the rated mains voltage is 230 V.

3.

Set up a fixed connection and install a partition with a contact opening of at least 3 mm (e.g. fuses or power switches).

4.

Provide one common electricity supply for the boiler and for the corresponding controller:

– Power supply: Single-phase, 230 V, 50 Hz

– Fuse protection: ≤ 3 A

5.

Open the electronics box. (→ Page 14)

6.

Observe the routing of the power supply cable (1) in the electronics box in order to guarantee the strain relief.

24V / eBus

1

2

24-V eBUS cable route

230-V eBUS cable route

5.6.3

Carrying out the wiring

L N

RT

X1

230V~

30 mm max.

1.

Shorten the connection cables to the appropriate lengths to prevent them from causing damage inside the electronics box.

2.

Screw the plug to the connection cable.

3.

Plug the plug into the slot provided on the PCB.

7.

Carry out the wiring. (→ Page 14)

8.

Close the electronics box.

9.

Make sure that access to the mains connection is always available and is not covered or blocked.

14


5.6.5

Connecting controllers to the electronic system

X22

4

24 V BUS

Burner off

24V=

RT

1 2 3

X2

X41

1

2

Safety thermostat for floor-standing heating

24 V controller

3

4 eBUS controller or radio receiver unit

Outside temperature sensor, wired

1.


2.

Carry out the wiring. (→ Page 14)

3.

Connect the individual components depending on the type of installation.

Conditions: If installing a multi-circuit controller.

▶

Change the pump's operating mode d.18 from Eco (intermittently operating pump) to Comfort (continuously operating pump).

Conditions: When connecting a controller (230 V).

Operation 6

6 Operation

6.1

Using diagnostics codes

You can use the parameters marked as adjustable in the table of diagnostics codes to adapt the product to the system and customer requirements.

Overview of diagnostics codes (→ Page 25)

6.1.1

Activating diagnostics codes

1.

Press and hold the button for seven seconds.

◁ is shown in the display.

2.

Press the buttons to set the value.

◁

The access code (96) is reserved for the competent person.

◁

The access code (35) is reserved for the customer service.

3.

Press the button to confirm.


6.1.2

Setting a diagnostics code

1.

Press the or code.

button to select the diagnostics

2.

Press the button to confirm.

◁

The value and/or status of the diagnostics code is shown in the display.

3.

Press the or button to set the value.

4.

If you allow the value to flash for three seconds, the setting is automatically confirmed.

◁ is shown in the display for 1 second.

Note

You can manually confirm the setting at any time by pressing and holding the button for less than 3 seconds.

L N

RT

X1

230V~

▶

Connect the controller to the main plug.

▶

Remove the bridge from the plug 24V=RT.

4.


5.

Proceed accordingly for all parameters that need to be changed.

6.

Press and hold the button for 3 seconds to finish configuring the diagnostics codes.

◁

The display switches to the basic display.

6.2

Displaying the status codes

The status codes display the product's current operating status.

Status codes – Overview (→ Page 28)

6.2.1

Activating the status codes display

1.

Hold the button down for more than 7 seconds.

◁

S.XX is shown on the display, followed by the heating flow temperature, the internal system pressure and the cylinder temperature (depending on the version).

2.

Press the button to exit this menu.


15

7 Start-up

◁

The display switches to the basic display.

6.3

Using check programmes

By activating various check programmes, you can trigger various special functions on the product.

Check programmes – Overview (→ Page 24)

6.3.1

Activating check programmes

1.

Press and hold the button for more than five seconds.


2.

Press and hold the button for five seconds.


3.

Press the

4.

Press the button to select the check programme.

button to confirm.

◁

The selected check programme is started.

5.

Press the button to finish the check programme.

6.

Press and hold the button for three seconds to finish the check programmes.

7.3

Checking the factory setting

The product's combustion has been factory tested and is preset for operation with the gas group indicated on the identification plate.

▶

Check the information about the type of gas indicated on the identification plate and compare this with the type of gas available at the installation location.

Conditions: The product design is not compatible with the local gas group

▶

Do not start up the product.

Conditions: The product design is compatible with the local gas group

▶

Proceed as described below.

7.4

Checking and treating the heating water/filling and supplementary water

Caution.

Risk of material damage due to poor-quality heating water

▶

Ensure that the heating water is of sufficient quality.

6.3.2

Activating the check programme for the maximum output function

▶

Press and hold the and buttons simultaneously for more than five seconds.

7

7.1

Start-up

Carrying out the initial start-up

Initial start-up must be carried out by a customer service technician or an authorised competent person using the firstcommissioning-checklist. The first-commissioning-checklist in the appendix (→ Page 35) of the installation instructions must be filled in and stored carefully along with the unit's documentation.

▶

Carry out the initial start-up using the first-commissioning-checklist in the appendix.

▶

Fill out and sign the first-commissioning-checklist.

7.2

Note

If you do not press any button for 15 minutes, the current programme is automatically cancelled and the basic display is shown.

Checking the type of gas

Make sure that the product is set up correctly by checking the type of gas. This ensures optimum combustion quality.

▶

Check the type of gas as part of routine product maintenance work when replacing components, carrying out work on the gas route and carrying out a gas conversion.

▶

Before filling or topping up the system, check the quality of the heating water.

Checking the quality of the heating water

▶

Remove a little water from the heating circuit.

▶

Check the appearance of the heating water.

▶

If you ascertain that it contains sedimentary materials, you must desludge the system.

▶

Use a magnetic rod to check whether it contains magnetite (iron oxide).

▶

If you ascertain that it contains magnetite, clean the system and apply suitable corrosion-protection measures, or fit a magnet filter.

▶

Check the pH value of the removed water at 25 °C.

▶

If the value is below 6.5 or above 8.5, clean the system and treat the heating water.

▶

Ensure that oxygen cannot get into the heating water.

(→ Page 19)

Checking the filling and supplementary water

▶

Before filling the system, measure the hardness of the filling and supplementary water.

Treating the filling and supplementary water

▶

Observe all applicable national regulations and technical standards when treating the filling and supplementary water.

Provided the national regulations and technical standards do not stipulate more stringent requirements, the following applies:

You must treat the heating water in the following cases:

– If the entire filling and supplementary water quantity during the operating life of the system exceeds three times the nominal volume of the heating installation, or

– If the guideline values listed in the following table are not met, or

16


– if the pH value of the heating water is less than 6.5 or more than 8.5.

Total heating output kW

< 50

Water hardness at specific system volume

1)

≤ 20 l/kW

> 20 l/kW

≤ 50 l/kW

> 50 l/kW ppm

CaCO₃ mol/m³

ppm


ppm


< 300 < 3 200 2 2 0.02

> 50 to ≤ 200

> 200 to ≤ 600

> 600

200

150

2

1.5

150

2

1.5

0.02

2

2

0.02

0.02

2 0.02

2 0.02

2 0.02

1) Nominal capacity in litres/heating output; in the case of multiboiler systems, the smallest single heating output is to be used.

Start-up 7

Additives for frost protection intended to remain permanently in the system

– Fernox Antifreeze Alphi 11

– Sentinel X 500

▶

If you have used the above-mentioned additives, inform the operator about the measures that are required.

▶

Inform the operator about the measures required for frost protection.

7.5

Filling the condensate siphon

2

Caution.

The use of unsuitable heating water may cause aluminium corrosion and a resulting lack of leak-tightness.

In contrast to steel, grey cast iron or copper, for example, aluminium reacts with alkaline heating water (pH value > 8.5) to produce substantial corrosion.

▶

When using aluminium, make sure that the pH value of the heating water is between 6.5 and a maximum of 8.5.

C

1

A

B

3

Caution.

Risk of material damage if the heating water is treated with unsuitable additives.

Unsuitable additives may cause changes in the components, noises in heating mode and possibly subsequent damage.

▶

Do not use any unsuitable frost and corrosion protection agents, biocides or sealants.

1.

Unclip the lower section of the siphon (1) from the upper section of the siphon (2).

2.

Remove the float (3).

3.

Fill the lower section of the siphon with water up to

10 mm below the upper edge of the condensate drain pipework.

4.

Re-insert the float (3).

Note

Check whether the float is present in the condensate siphon.

No incompatibility with our products has been detected to date with proper use of the following additives.

▶

When using additives, follow the manufacturer's instructions without exception.

We accept no liability for the compatibility of any additive or its effectiveness in the rest of the heating system.

Additives for cleaning measures (subsequent flushing required)

– Fernox F3

– Sentinel X 300

– Sentinel X 400

Additives intended to remain permanently in the system

– Fernox F1

– Fernox F2

– Sentinel X 100

– Sentinel X 200

5.

Clip the lower section of the siphon (1) into the upper section of the siphon (2).

7.6

Switching on the product

▶

Switch on the product via the main switch installed onsite.


17

7 Start-up

7.7

Checking the gas connection pressure (gas flow pressure)

1.

Close the gas isolator cock.

2

1

▶


7.8

Checking the CO₂ content

1.

Start up the product with the check programme P.01.

2.

Wait at least five minutes until the product reaches its operating temperature.

3.

Measure the CO₂ content at the flue gas analysis point.

4.

Compare the measured value with the corresponding value in the table.

Settings Unit G20 natural gas

CO₂ after 5 minutes in full load mode with front casing closed

CO₂ after 5 minutes in full load mode with front casing removed

Set for Wobbe index W₀

CO in full load mode

CO/CO₂

Vol.–% 9.2 ± 1.0

Vol.–% 9.0 ± 1.0

kWh/m³ ppm

15

≤ 250

≤ 0.0031

5.

Set the CO₂ content as required. (→ Page 18)

7.9

Setting the CO₂ content

1

2.

Use a screwdriver to undo the sealing screw on the measuring connection (1) of the gas valve.

3.

Connect a pressure gauge (2) to the measuring nipple

(1).

4.

Open the gas isolator cock.

5.

Start up the product with the check programme P.01.

6.

Measure the gas connection pressure against atmospheric pressure.

Permissible connection pressure

Great Britain

Natural gas G20

1.7

… 2.5 kPa

(17.0

… 25.0 mbar)

7.

Decommission the product.

8.


9.

Remove the pressure gauge.

10. Tighten the screw on the measuring nipple (1).

11. Open the gas isolator cock.

12. Check the measuring nipple for gas tightness.

Conditions: Gas connection pressure not in the permissible range

Caution.

Risk of material damage and operating faults caused by incorrect gas connection pressure.

If the gas connection pressure lies outside the permissible range, this can cause operating faults in and damage to the product.

▶

Do not make any adjustments to the product.

▶

Do not start up the product.

▶

If you are unable to remedy the fault, contact the gas supply company.

1.

Remove the yellow sticker.

2.

Remove the blue covering cap (1).

3.

Use an Allen key to turn the bolt in order to set the CO₂ content (value with front casing removed).

◁

Turning to the right decreases the value.

◁

Turning to the left increases the value.

4.

For natural gas only: Only perform the adjustment in increments of a 1/8 turn and wait approx. one minute after each adjustment until the value stabilises.

5.

For liquid gas only: Only perform the adjustment in small increments (approx. 1/16 turn), and wait approx.

one minute after each adjustment until the value stabilises.

6.

If an adjustment is not possible in the specified adjustment range, you must not start up the product.

7.

If this is the case, inform Vaillant Customer Service.

8.

Secure the covering cap.

9.

Install the front casing. (→ Page 10)

18


Adapting the unit to the heating installation 8

7.10

Checking the leak-tightness of the flue gas system and for flue gas recirculation

1.

Check that the flue gas system is intact, in accordance with British Gas TB 200.

2.

If the flue gas system is longer than 2 m, we urgently recommend that you test the system for flue gas recirculation as described below.

3.

Use the air analysis point (1) to check for flue gas recirculation.

4.

Use the flue gas measuring instrument.

5.

If you discover CO or CO2 in the fresh air, search for a leak in the flue gas system or for the flue gas recirculation.

6.

Eliminate the damage.

7.

Repeat the above-mentioned test to determine if the fresh air contains CO or CO2.

8.

If you cannot eliminate the damage, you must not start up the boiler.

7.11

Checking function and leak-tightness

Before you hand the product over to the operator:

▶

Check the gas line, the flue gas installation, the heating installation and the hot water pipes for leaks.

▶

Check that the air/flue pipe and condensate drain pipework have been installed correctly.

▶

Check that the front casing has been installed correctly.

7.12

Checking the heating mode

1.

Activate the heating mode on the user interface.

2.

Turn all thermostatic radiator valves on the radiators until they are fully open.

3.

Allow the product to operate for at least 15 minutes.

4.

Purge the heating installation.

5.

Activate the display for the current operating status.

(→ Page 15)

Status codes – Overview (→ Page 28)

◁

If the product is working correctly, the display shows

S.04.

8 Adapting the unit to the heating installation

You can reset/change the system parameters (section "Using diagnostics codes").


8.1

Burner anti-cycling time

To prevent frequent switching on and off of the burner and thus prevent energy losses, an electronic restart lockout is activated for a specific period each time the burner is switched off. The burner anti-cycling time is only active for the heating mode. Hot water handling mode during a burner anti-cycling time does not affect the time function element.

8.1.1

Setting the burner anti-cycling time

▶

Set the diagnostics code. (→ Page 15)


8.1.2

Resetting the remaining burner anti-cycling time

▶

Press and hold the fault clearance key for more than three seconds.


9 Handing the product over to the operator

▶

When you have finished the installation, attach the sticker supplied (in the operator's language) to the product cover.

▶

Explain to the operator how the safety devices work and where they are located.

▶

Inform the operator how to handle the product.

▶

In particular, draw attention to the safety information which the operator must follow.

▶

Inform the operator of the necessity to have the product maintained on a regular basis.

▶

Instruct the operator about measures taken to ensure the supply of combustion air and flue gas pipe.

10 Inspection and maintenance

10.1

Observing inspection and maintenance intervals

▶

Adhere to the minimum inspection and maintenance intervals. The inspection may require maintenance to be carried out earlier, depending on the results.

Inspection and maintenance work – Overview

(→ Page 24)

10.2

Procuring spare parts

The original components of the product were also certified as part of the declaration of conformity. If you do not use certified Glow-worm original spare parts for maintenance or repair work, this voids the conformity of the product. We therefore strongly recommend that you install Glow-worm original spare parts. Information about available Glow-worm original spare parts is available by contacting the contact address provided on the reverse of this document.

▶

If you require spare parts for maintenance or repair work, use only Glow-worm original spare parts.


19

10 Inspection and maintenance

10.3

Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three main components:

– Ventilator

– Gas valve

– Burner cover

1.

Switch off the product via the main switch.

2.


3.

Remove the front casing. (→ Page 10)

B

D

C

A

1

A

7.

Remove the plugs from the gas valve.

8.

Remove the gas-air mixture unit.

9.

Remove both burner seals from the burner cover.

1

4.

Remove the air intake pipe (1).

B

A

C

B

2

10. Remove the burner (4).

10.4

Cleaning the heat exchanger

1.

Check the heat exchanger for damage and dirt.

2.

If required, clean and replace the heat exchanger.

1

3

3.

Protect the folded down electronics box against sprayed water.

4.

Clean the ribs of the heat exchanger (1) with water.

◁

The water runs out via the condensate tray.

5.

Push the clip (2) upwards.

6.

Remove the flue pipe (3).

20


Troubleshooting 11

10.5

Checking the burner

▶

Check the surface of the burner for damage. If you see any damage, replace the burner.

10.6

Checking the ignition electrode

2

1

3 4 5

1.

Disconnect the connection (2) and the earthing cable

(1).

2.

Remove the fixing screws (3).

3.

Carefully remove the electrode from the combustion chamber.

4.

Check that the electrode ends (4) are undamaged.

5.

Check the electrode distance.

– Clearance for the ignition electrodes: 3.5 … 4.5 mm

6.

Make sure that the seal (5) is free from damage.

▽

If necessary, replace the seal.

10.7

Cleaning the condensate siphon

10.8

Installing the gas-air mixture unit

1.

Install the burner.

2.

Install two new burner seals in the burner cover.

3.

Install the gas-air mixture unit.

4.

Install the flue pipe.

5.

Install the air intake pipe.

10.9

Draining the product

1.

Close the service valves of the product.

2.

Start check programme P.05 (→ Page 16).


3.

Open the drain valves.

10.10 Completing inspection and maintenance work

1.

Check the gas connection pressure (gas flow pressure).

(→ Page 18)

2.

Check the CO₂ content. (→ Page 18)

2

1

A

B

3

11 Troubleshooting

11.1

Rectifying faults

▶

If fault codes (F.XX) are present, refer to the table in the appendix for advice or use the check programme(s).

Overview of fault codes (→ Page 29)


If several faults are present at the same time, the fault codes are displayed alternately followed by the time at which the respective fault occurred.

▶

Hold the button down for more than 3 seconds.

▶

If you are unable to clear the fault code and it reappears despite several fault clearance attempts, contact customer service.

11.2

Calling up the fault memory

The last ten fault codes are stored in the fault memory (together with the time at which the respective fault occurred).

▶

Press and hold the button for more than seven seconds.

Overview of fault codes (→ Page 29)

▶

Press the button to exit this menu.

11.3

Deleting the fault memory

▶

Delete the fault memory (d.94).


1.

Unclip the lower section of the siphon (1) from the upper section of the siphon (2).

2.

Remove the float (3).

3.

Flush out the lower section of the siphon with water.

4.

Reinsert the float (3).

Note

Check whether the float is present in the condensate siphon.

5.

Clip the lower section of the siphon (1) into the upper section of the siphon (2).


21

11 Troubleshooting

11.4

Preparing the repair work

1.

Decommission the product.

2.

Disconnect the product from the power mains.

3.

Remove the front casing.

4.


5.

Close the service valves in the heating flow and in the heating return.

6.

Close the service valve in the cold water pipe.

7.

Drain the product if you want to replace water-bearing components of the product.

8.

Make sure that water does not drip on live components

(e.g. the electronics box).

9.

Use only new seals.

11.5

Replacing defective components

11.5.1 Replacing the burner

1.

Remove the gas-air mixture unit. (→ Page 20)

2.

Remove the burner seal.

3.

Remove the burner.

4.

Install the new burner complete with new seal on the heat exchanger.

5.

Install the gas-air mixture unit. (→ Page 21)

11.5.2 Replacing the gas-air mixture unit

1.


2.

Install the new gas-air mixture (→ Page 21).

11.5.3 Replacing the heat exchanger

1.

Remove the side section. (→ Page 10)

2.


5.

Remove the gas pipe.

3

B

B

A

A

A

6.

Undo the clip underneath the condensate tray (4).

7.

Undo the two screws (3).

4

5

A

C

B

C

1

2

B

8.

Lift the heat exchanger up slightly and remove it together with the condensate tray.

9.

Remove the ignition transformer (5).

10. Replace all the seals.

11. Install the new heat exchanger in reverse order.

E

D

3.

Remove the flow pipe (1).

4.

Remove the return pipe (2).

22


11.5.4 Replacing the main PCB

A

A

1.


2.

Pull all of the plugs out from the PCB.

3.

Undo the clips on the PCB.

4.

Remove the PCB.

5.

Install the new PCB in such a way that it clicks into the groove at the bottom and into the clip at the top.

6.

Plug in the PCB plugs.

7.


11.5.5 Replacing the PCB for the user interface

Decommissioning the product 12

11.6

Completing repair work

▶

Check that the product functions correctly and is leaktight (→ Page 19).

12 Decommissioning the product

▶

Switch off the product.

▶

Disconnect the product from the power mains.

▶


▶

Close the cold water stop valve.

▶

Drain the product. (→ Page 21)

13 Customer service

For contact details for our customer service department, you can write to the address that is provided on the back page, or you can visit www.glow-worm.co.uk.

C

C

D

B

A

A

1.


2.

Pull the plug out of the PCB.

3.

Undo the clips on the PCB.

4.

Remove the PCB.

5.

Install the new PCB in such a way that it clicks into the groove at the bottom and into the clip at the top.

6.

Plug in the PCB plug.

7.



23

Appendix

Appendix

A

Inspection and maintenance work – Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals. If national regulations and directives require shorter inspection and maintenance intervals, you should observe these instead of the intervals listed in the table.

No.

Work

Inspection

(annual)

Maintenance

(at least every

2 years)

1

2

3

4

5

6

Check the air/flue pipe for leak-tightness and to ensure that it is fastened correctly. Make sure that it is not blocked or damaged and has been installed in accordance with the relevant Installation Manual.

Check the general condition of the product. Remove dirt from the product and from the vacuum chamber.

Visually inspect the general condition of the entire heating cell and, in particular, check for signs of corrosion, soot or other damage. If you notice any damage, carry out maintenance work.

Check the gas connection pressure at maximum heat input. If the gas connection pressure is not within the correct range, carry out maintenance work.

Check the CO₂ content (the air ratio) of the product and, if necessary, adjust it. Keep a record of this.

Disconnect the product from the power mains. Check that the electrical plug connections and other connections are seated correctly and correct these if necessary.

Close the gas isolator cock and the service valves.

7

8

Drain the product on the water side.

9

Remove the gas-air mixture unit.

10

Check the seals in the combustion area. If you see any damage, replace the seals. Replace the burner seal each time it is opened and accordingly each time maintenance is carried out.

11 Clean the heat exchanger.

12 Check the burner for damage and replace it if necessary.

13

Check the condensate siphon in the product, clean and fill if necessary.

14

Install the gas-air mixture unit. Caution: Replace the seals.

15

Open the gas isolator cock, reconnect the product to the power mains and switch the product on.

16

Open the service valves, fill the product/heating installation.

17

Perform a test operation of the product and heating installation, including hot water generation, and purge the system once more if necessary.

18

Visually inspect the ignition and burner behaviour.

19 Check the CO₂ content (the air ratio) of the product again.

20 Check the product for gas, flue gas, hot water and condensate leaks, and repair if necessary.

21 Record the inspection/maintenance work carried out.

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

B

Check programmes – Overview

Note

Since the programme table is used for various products, some programmes may not be visible for the product in question.

Display

P.01

P.02

Meaning

Start up the burner at the adjustable heat input:

The product is operated after a successful ignition with the set heat input between "0" (0% = Pmin) and

"100" (100% = Pmax).

The function is activated for 15 minutes.

Start up the burner at ignition load:

The product is operated at ignition load after successful ignition.


24


Appendix

Display

P.03

P.04

P.05

P.06

P.07

P.10

Automatic purging function

Meaning

The product runs in heating mode with the maximum heat input set using diagnostics code d.00.

Maximum output function:

If there is a hot water request, the product runs in hot water handling mode with maximum heat input.

If there is no hot water request, the product runs in heating mode with the heating partial load that is set using diagnostics code d.00.


Filling the product:

The diverter valve is moved to the mid-position. The burner and pump are switched off (to fill or drain the product).

If the pressure is lower than 0.05 MPa (0.5 bar) and then is above 0.07 MPa (0.7 bar) for longer than 15 seconds, the automatic purging function is activated.


Purging the heating circuit:

The diverter valve is moved to the heating position.

The function is activated in the heating circuit for 15 minutes.

The pump runs and stops at regular intervals.

If required, this function can be manually switched off.

Purging the hot water circuit:

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute.

The pump runs and stops at regular intervals.

If required, this function can be manually switched off.

Safety cut-out check

Purging the product:

If the pressure is lower than 0.05 MPa (0.5 bar) and then is above 0.07 MPa (0.7 bar) for longer than 15 seconds, the automatic purging function is activated.

The function is activated in the small hot water circuit for 4 minutes and then in the heating circuit for 1 minute.

This function cannot be manually switched off.

C Overview of diagnostics codes

Setting level d.00 Heating maximum output

Values

Min.

–

Max.

–

Unit

kW min

Increment, select, explanation

The maximum heating output varies depending on the product.

→ Section "Technical data"

1

Default setting

→ Section

"Technical data"

5

Own setting

Adjustable

Adjustable

d.01 Pump overrun in heating mode d.02 Burner anti-cycling time in heating mode d.04 Water temperature in the cylinder d.05 Determined heating flow set target temperature d.07 Set target temperature for the domestic hot water cylinder d.08 Status of the 230 V thermostat

1

2

60

60

Current value

Current value

Current value

Current value

d.09 Heating flow set target temperature that is set on the eBUS room thermostat d.10 Status of the internal pump in the heating circuit d.11 Status of the heating circuit's shunt pump

Current value

Current value

Current value

–

–

–

– min

℃

℃

℃

1

–

–

–

0 = Room thermostat open (no heat requirement)

1 = Room thermostat closed (heat requirement)

– off / on off / on

–

–

20

–

–

–

–

–

Adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable


25

Appendix

Setting level d.13 Status of the hot water circuit's circulation pump d.16 Status of the 24 V room thermostat d.17 Heating control d.18 Pump overrun operating mode

Values

Min.

Max.

Current value

Current value

– –

1 3

d.20 Maximum hot water set target temperature d.23 Status of the heating demand d.24 Status of the pressure monitor d.25 Status of the requirement to reheat the cylinder or for the hot water warm start from the eBUS thermostat d.27 Function of relay 1 (multifunctional module)

Current value

0

50

Current value

1

60

1

10

d.28 Function of relay 2 (multifunctional module) d.31 Automatic filling device d.33 Fan speed target value d.34 Value for the fan speed

1

0

10

2

Current value

Current value

d.40 Heating flow temperature

Current value

d.41 Heating return temperature d.43 Heating curve

Current value

0.2

4

Unit

–

–

–

–

℃

–

–

–


off / on off = Heating off on = Heating on off = Flow temperature on = Return temperature (adjustment for underfloor heating. If you have activated the return temperature control, the automatic heating output determination function is not active.)

1 = Comfort (continuously operating pump)

3 = Eco (intermittent pump mode – for the dissipation of the residual heat after hot water generation at an extremely low heat demand)

1

Default setting

–

–

0

Own setting

Not adjustable

Not adjustable

Adjustable

1

50

Adjustable

Adjustable off = Heating off (Summer mode) on = Heating on off = Not switched on = Switched off = Function deactivated on = Function activated

–

–

–

– rpm rpm

℃

℃

–

–

1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = External fault message

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = External fault message

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

0 = Manual

1 = Semi-automatic

2 = Automatic

Fan speed = Display value x 100


0.1

–

–

–

1

2

0

–

–

–

–

1.2

Not adjustable

Not adjustable

Not adjustable

Adjustable

Adjustable

Adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Adjustable

26


Appendix

Setting level d.45 Value for the base point of the heating curve d.47 Outside temperature d.50 Correction of the minimum fan speed d.51 Correction of the maximum fan speed d.58 Solar circuit reheating

Values

Min.

15

Max.

30

Current value

0 3000

-2500

0

0

3

d.60 Number of blocks by the temperature sensor d.61 Number of successful ignitions d.62 Night set-back d.64 Average burner ignition time d.65 Maximum burner ignition time d.66 Activation of the warm start function for hot water d.67 Remaining burner anticycling time (setting under d.02) d.68 Number of unsuccessful ignitions at 1st attempt d.69 Number of unsuccessful ignitions at 2nd attempt d.71 Maximum heating flow set target temperature d.75 Maximum cylinder reheating time d.77 Max. cylinder reheating

Current value

Current value

0 30

Current value

Current value

–

Current value

Current value

Current value

45

20

–

–

80

90

– min min kW

d.78 DHW max. flow temperature d.80 Running time in heating mode d.81 Running time in DHW mode d.82 Number of burner ignitions in heating mode d.83 Number of burner ignitions in DHW mode d.84 Maintenance in

50

Current value

Current value

Current value

Current value

0

80

3000

℃ h h

–

– h

d.85 Increase in the min. output (heating and DHW mode) d.90 Status of the eBUS room thermostat d.93 Setting the product code d.94 Delete fault list

–

0

0

–

Current value

99

1 kW

–

–

– s

–

–

–

℃

–

–

– s

Unit

–

℃ rpm rpm

–

–

–


1

–

1

–

–

1


1


0 = Boiler's Legionella protection function deactivated

3 = Hot water activated (target value min. 60 °C)

–

– off = Function deactivated on = Function activated

–

Default setting

20

Own setting

Adjustable

–

600

Not adjustable

Adjustable

-1000

0

–

–

0

–

–

1

–

Adjustable

Adjustable

Not adjustable

Not adjustable

Adjustable

Not adjustable

Not adjustable

Adjustable

Not adjustable

1

–

–

75

Not adjustable

Not adjustable

Adjustable

1

–

–

1

→ Section "Technical data"

1

–

45

–

Adjustable

Adjustable

Number of ignitions = Display value x

100

Number of ignitions = Display value x

100

Number of hours = Display value x 10

1

→ Section "Technical data" off = Not connected on = Connected

1 off = No on = Yes

–

–

–

–

300

–

–

–

–

Adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Adjustable

Not adjustable

Adjustable

Adjustable


27

Appendix

Setting level d.95 Software versions d.96 Reset to factory setting

Values

Min.

–

Max.

–

– –

Unit

–

–

℃

℃


1 = Main PCB

2 = Interface PCB

0 = No

1 = Yes

1

Default setting

–

Own setting

Adjustable

–

Adjustable

d.128 Heating minimum target value d.129 Hot water minimum target value

10

35

(combination unit)

45

(pure boiler)

75

60 1

10

35

Adjustable

Adjustable

S.20

S.21

S.22

S.23

S.24

S.25

S.26

S.27

S.28

S. 0

S.01

S.02

S.03

S.04

S.05

S.06

S.07

S.08

S.30

S.31

S.32

S.34

S.39

S.42

S.46

S.53

S.54

S.88

S.91

S.96

D

Status codes – Overview

Status code Meaning

Heating mode: No requirement

Displays in heating mode

Heating mode: Advance fan operation

Heating mode: Pump pre-run

Heating mode: Burner ignition

Heating mode: Burner on

Heating mode: Pump/fan overrun

Heating mode: Fan overrun

Heating mode: Pump overrun

Heating mode: Temporary shutdown after heating procedure

Display in hot water handling mode with cylinder

Hot water handling mode: Requirement

Hot water handling mode: Advance fan operation

Hot water handling mode: Pump pre-run

Hot water handling mode: Burner ignition

DHW mode: Burner on

DHW mode: Pump/fan overrun

DHW mode: Fan overrun

DHW mode: Pump overrun

Hot water handling mode: Temporary shutdown of the burner

Other displays

Room thermostat is blocking heating mode.

No heating demand: Summer mode, eBUS controller, waiting period

Fan waiting time: Fan speed outside of the tolerance values

Frost protection active

Underfloor heating contact open

Flue non-return flap closed

Frost protection mode (Comfort): Minimum load

Product in waiting period/operation block function due to low water pressure (flow/return spread too large)

Waiting period: Low water pressure in the circuit (flow/return spread too large)

Product purging active

Maintenance: Demo mode

Automatic test programme: Return temperature sensor, heating demands blocked.

28


Appendix

Status code

S.98

S.99

S.108

S.109

Meaning

Automatic test programme: Return temperature sensor, heating demands blocked.

Internal automatic test programmes

Purging the combustion chamber, fan in operation

Product's standby mode activated

E Overview of fault codes

Fault code

F.00

F.01

F.10

F.11

F.12 and

F.91

F.13

F.20

F.23

F.24

F.25

F.27

F.28

F.29

F.32

F.33

F.49

F.61

F.62

F.63

F.64

F.65

Meaning Possible cause

Fault: Flow temperature sensor

Fault: Return temperature sensor

Short circuit: Flow temperature sensor

Short circuit: Return temperature sensor NTC sensor defective, short circuit in the cable harness, cable/casing

Short circuit: Cylinder temperature sensor

Short circuit: Domestic hot water cylinder temperature sensor

Safety switch-off: Overheating temperature reached

NTC sensor defective, short circuit in the cable harness, cable/casing


Safety switch-off: Temperature difference too great (NTC1/NTC2)

Safety switch-off: Temperature rise too fast

Incorrect earth connection between cable harness and product, flow or return

NTC defective (loose connection), black discharge via ignition cable, ignition plug or ignition electrode

Pump blocked, insufficient pump output, air in product, flow and return NTC sensors connected the wrong way round

Pump blocked, insufficient pump output, air in product, system pressure too low, non-return valve blocked/incorrectly installed

Safety switch-off: Flue gas temperature too high

Break in plug connection for optional flue gas safety temperature limiter

(STB), break in cable harness

Safety switch-off: Fault in flame detection Moisture on the electronics, electronics (flame monitor) defective, gas solenoid valve leaking

Fault: Ignition unsuccessful when starting up

Fault: Flame loss

Gas meter defective or gas pressure monitor has triggered, air in gas, gas flow pressure too low, thermal isolator device (TAE) has triggered, incorrect gas restrictor, incorrect spare gas valve, fault on the gas valve, multiple plug on PCB incorrectly plugged in, break in cable harness, ignition system (ignition transformer, ignition cable, ignition plug, ignition electrode) defective, ionisation current interrupted (cable, electrode), incorrect earthing of product, electronics defective

Gas supply temporarily stopped, flue gas recirculation, incorrect earthing of product, ignition transformer has spark failure

Fan frost protection function active: Fan speed outside the tolerance values

Fan frost protection function active: Air pressure switch fault eBUS fault: Voltage too low

Fault: Gas valve control system

Fault: Gas valve switch-off control

Fault: EEPROM

Plug on fan not correctly plugged in, multiple plug on PCB not correctly plugged in, break in cable harness, fan blocked, Hall sensor defective, electronics defective

Pressure monitor has not switched or has switched at a fan speed value that is too high (insufficient air supply)

Pressure monitor plug not correctly plugged in, pressure monitor defective, hose removed from between the pressure monitor and silencer, air/flue pipe blocked

Short circuit on eBUS, eBUS overload or two power supplies with different polarities on the eBUS

Short circuit/short to earth in cable harness for the gas valve, gas valve defective (coils shorted to earth), electronics defective

Delayed switch-off of gas valve, delayed extinguishing of flame signal, gas valve leaking, electronics defective

Electronics defective

Fault: Electronics/sensor/analogue-todigital converter

Fault: Electronics temperature too high

NTC plug not plugged in or has come loose, multiple plug on the PCB not plugged in correctly, interruption in cable harness, NTC sensor defective

NTC plug not plugged in or has come loose, multiple plug on the PCB not plugged in correctly, interruption in cable harness, NTC sensor defective


Flow or return NTC short circuited, electronics defective

Electronics overheating due to external influences, electronics defective


29

Appendix

F.71

F.72

F.77

F.78

F.83

Fault code

F.67

F.68

F.70

Meaning

Value sent back by ASIC is incorrect

(flame signal)

Fault: Unstable flame (analogue input)

Invalid product code (DSN)

Fault: Flow/return temperature sensor

Fault: Deviation in the water pressure sensor/return temperature sensor

Fault: Condensate or smoke

Interruption to DHW outlet sensor at external controller

Fault: Burner temperature sensor

F.84

F.85

F.86

F.87

F.88

Connection

Fault: Flow/return temperature sensor

Fault: Temperature sensor

Fault: Underfloor heating contact

Fault: Electrodes

Fault: Gas valve

No communication between the PCB and the user interface

Possible cause

Implausible flame signal, electronics defective

Air in gas, gas flow pressure too low, incorrect air ratio, incorrect gas restrictor, ionisation flow interruption (cable, electrode)

Display and PCB replaced at same time and Device Specific Number not reset, wrong or missing output range coding resistance

Flow temperature sensor signalling constant value: Flow temperature sensor incorrectly positioned on supply pipe, flow temperature sensor defective

Flow/return NTC temperature difference too great → flow and/or return temperature sensor defective

No response, flue non-return flap defective

UK link box is connected, but hot water NTC not bridged

Burner temperature sensor is defective

When the burner starts, the temperature change registered at the flow or return temperature sensor is non-existent or too small: Insufficient water in the product, the flow or return temperature sensor is not in the correct position on the pipe

Values not consistent, difference < -6 K

Flow and return temperature sensors signalling implausible values: Flow and return temperature sensors have been inverted, flow and return temperature sensors have not been correctly installed

The flow and/or return temperature sensors have been installed on the same pipe/incorrect pipe

Temperature sensor not connected or is connected incorrectly

Underfloor heating contact open, sensor disconnected or defective

Electrodes not connected or they are connected incorrectly, short circuit in the cable harness

Gas valve not connected or it is connected incorrectly, short circuit in the cable harness

Electronics defective

30


F Connection diagram

X51

X51

2

3

4

1

2

5

6

1

X51

X40 X51

X32 X35

Burner off

24V=

RT

X20

X12

X21

X30

RT

Main PCB

Interface PCB

Control system

Temperature sensor in the heating flow

Temperature sensor in the heating return

Fan

Burner off

X106 eBUS

13

X20

4

15

3

16

6

5

1

9

8

3

1

2

3

4

5

1

M

24V

230V~

6

7

4

5

X14

N

L

X21

N

L

X1

RT

N

L

X12

7

8

9

10

11

L

N

9

10

Gas valve

Monitoring electrode

Room thermostat

Main power supply

Ignition electrode

11

Appendix


31

Appendix

G Connection diagram, 30 kW

X51

X51

2

3

4

1

2

5

6

1

X51

X40 X51

X32 X35

Burner off

24V=

RT

X20

X12

X21

X30

RT

Main PCB

Interface PCB

Control system

Temperature sensor in the heating flow

Temperature sensor in the heating return

Fan

Burner off

X106 eBUS

13

X20

4

15

3

16

6

5

1

9

8

3

1

2

3

4

5

1

M

24V

230V~

6

7

4

5

X14

N

L

X21

N

L

X1

RT

N

L

X12

7

8

9

10

11

L

N

9

10

Gas valve

Monitoring electrode

Room thermostat

Main power supply

Ignition electrode

11

32


H Opening in the flue pipe

J

L

G

B

A

II

C

P

R

S

T

D, E

H

O

H

N

N

K

Appendix

A

B

C

D

I

G

H

J

K

E

F

L

M

N

O

P

Q

R

S

T

H.1

Positioning of the opening of a fan-supported flue gas pipe

Installation site

Directly below an opening, air bricks, opening windows, etc., that can be opened.

Above an opening, air bricks, opening windows, etc., that can be opened.

Horizontally to an opening, air bricks, opening windows, etc., that can be opened.

Below temperature-sensitive building components, e.g. plastic gutters, down pipes or wastewater pipes

Below eaves

Below balconies or car port roofs

From vertical wastewater pipes or down pipes

From external or internal corners

Above floors, roofs or balconies

From a surface facing a terminal

From a terminal facing a terminal

From an opening in the car port (e.g. door, window) which leads into the dwelling

Vertical from a terminal on the same wall

Horizontal from a terminal on the same wall

From the wall on which the terminal has been installed

From a vertical structure on the roof

Above the roof area

Horizontal from adjacent windows on pitched or flat roofs

Above adjacent windows on pitched or flat roofs

Below adjacent windows on pitched or flat roofs

Minimum dimensions

300 mm

300 mm

300 mm

75 mm

200 mm

200 mm

150 mm

200 mm

300 mm

600 mm

1,200 mm

1,200 mm

1,500 mm

300 mm

0 mm

N/A

300 mm

600 mm

600 mm

2,000 mm


33

Appendix

H.2

Text from BS 5440-1 on fan-supported flue gas pipes

BS 5440–1: It is recommended that the fanned flue gas system terminal is positioned as follows:

– At least 2 m from an opening in the building directly opposite, and

– So that the combustion products are not discharged directly across a property boundary.

– Dimensions D, E, F and G: These clearances may be reduced to 25 mm without affecting the performance of the boiler.

In order to ensure that the condensate vapour plume does not damage adjacent surfaces, the terminal should be extended as shown.

– Dimension H: This clearance may be reduced to 25 mm without adversely affecting the performance of the boiler. However, in order to ensure that the condensate vapour plume does not damage adjacent surfaces, a clearance of 300 mm is preferred. For IE, recommendations are given in the current issue of the IS 813.

H.3

Opening of the flue pipe below eaves and balconies

Balcony/eaves

Gutter

Adequately secured air/flue gas pipe

The flue pipe must protrude beyond any overhang

34


I Commissioning Checklist

Benchmark Commissioning and

Servicing Section

It is a requirement that the boiler is installed and commissioned to the completed in full.

Appendix

www.centralheating.co.uk

© Heating and Hotwater Industry Council (HHIC)


35

Appendix

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

CONTROLS

ALL SYSTEMS

CENTRAL HEATING MODE

COMBINATION BOILERS ONLY

DOMESTIC HOT WATER MODE

CONDENSING BOILERS ONLY

ALL INSTALLATIONS

Optimum start control

Fitted

Fitted

Fitted

Fitted

Yes

Yes mbar

OR

OR

mbar

Yes

Yes mbar OR

AND

AND

OR

Yes Temperature

Yes

² Ratio

² Ratio

Yes

Yes

Yes

Yes mbar

36


SERVICE RECORD

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.

Service Provider

SERVICE 01 SERVICE 02

AND

AND

² %

² %

AND

AND

² %

² %

Appendix


AND

AND

² %

² %

AND

AND

² %

² %


AND

AND

² %

² %

AND

AND

² %

² %


AND

AND

² %

² %

AND

AND

² %

² %

SERVICE 09

SERVICE 10

AND

AND

² %

² %

AND

AND

² %

² %


37

Appendix

J Combustion chart

NOTE

THE AIR GAS RATIO VALVE IS FACTORY

SET AND MUST NOT BE ADJUSTED

DURING COMMISSIONING UNLESS THIS

ACTION IS RECOMMENDED FOLLOWING

CONTACT WITH THE MANUFACTURER.

If any such adjustment is recommended and further checking of the boiler is required the installer/service engineer must be competent to carry out this work and to use the flue gas analyser accordingly.

If the boiler requires conversion to operate with a different gas family (e.g. conversion from natural gas to LPG) separate guidance will be provided by the boiler manufacturer

VERIFY FLUE INTEGRITY

Analyser readings indicate that combustion products and inlet air must be mixing. Further investigation of the flue is therefore required.

Check that flue components are assembled, fixed and supported as per boiler/flue manufacturer’s instructions.

Check that flue and flue terminal are not obstructed.

Is

O

2

≥ 20.6% and

CO

2

< 0.2%

YES

NO

TURN OFF APPLIANCE AND CALL

MANUFACTURER’S TECHNICAL HELPLINE

FOR ADVICE.

THE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE

IDENTIFIED AND RESOLVED.

Check all seals around the appliance burner, internal flue seals, door and case seals.

Rectify where necessary.

Is

CO less than

335ppm and

CO/CO

2

ratio less than 0.004

YES

NO

TURN OFF APPLIANCE AND CALL

MANUFACTURER’S TECHNICAL HELPLINE

FOR ADVICE.

THE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE

IDENTIFIED AND RESOLVED. IF

COMMISSIONING CANNOT BE FULLY

COMPLETED, THE APPLIANCE MUST BE

DISCONNECTED FROM THE GAS SUPPLY IN

ACCORDANCE WITH THE GSIUR.

NOTE: Check and record CO and combustion ratio at both max. and min. rate before contacting the manufacturer.

NO

PRIOR TO CO AND COMBUSTION RATIO CHECK

The boiler manufacturer’s installation instructions should have been followed, gas type verified and gas supply pressure/rate checked as required prior to commissioning.

As part of the installation process, especially where a flue has been fitted by persons other than the

boiler installer, visually check the integrity of the whole flue system to confirm that all components are correctly assembled, fixed and supported. Check that manufacturer’s max. flue lengths have not been exceeded and all guidance has been followed (e.g. Gas Safe Technical Bulletin TB008).

The flue gas analyser should be of the correct type, as specified by BS 7967

Prior to its use, the flue gas analyser should have been maintained and calibrated as specified by the manufacturer. The installer must have the relevant competence for use of the analyser.

Check and zero the analyser IN FRESH AIR as per analyser manufacturer’s instructions.

SET BOILER TO MAXIMUM RATE

In accordance with boiler instructions, set boiler to operate at max. rate

(full load condition). Allow sufficient time for combustion to stabilise.

NOTE - Do not insert analyser probe during this period to avoid possible “flooding” of sensor.

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSER

Insert analyser probe into air inlet test point and allow readings to stabilise.

NOTE - where no air inlet test point is provided then a flue integrity check with the analyser is not possible. The installer should verify that flue integrity has been visually checked in accordance with the “Prior to CO

and combustion ratio check” box above before proceeding to the

“Check CO and combustion ratio at maximum rate” stage below.

NO

Is

O

2

≥ 20.6% and

CO

2

< 0.2%

YES

CHECK CO AND COMBUSTION RATIO AT MAX. RATE

With boiler still set at maximum rate, insert analyser probe into flue gas sampling point. Allow readings to stabilise before recording.

NOTE - If no flue gas sampling point is present and the correct procedure is not specified in the manual, consult boiler manufacturer for guidance.

NO

Is

CO less than

350ppm and

CO/CO

2


YES

SET BOILER TO MINIMUM RATE

In accordance with boiler instructions, set boiler to operate at minimum rate (to minimum load condition). Allow sufficient time for combustion to stabilise.

NOTE - If manufacturer’s instructions do not specify how to set boiler to minimum rate contact Technical Helpline for advice.

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATE

With boiler still set at minimum rate, insert analyser probe into flue gas sampling point. Allow readings to stabilise before recording.

NOTE - If no flue gas sampling point is present and the correct procedure is not specified in the manual, consult boiler manufacturer for guidance.

Is

CO less than

350ppm and

CO/CO

2


YES

BOILER IS OPERATING SATISFACTORILY no further actions required.

Ensure test points are capped, boiler case is correctly replaced and all other commissioning procedures are completed.

Complete Benchmark Checklist, recording CO and combustion ratio readings as required.

38


Appendix

K Technical data

Technical data – Heating

Max. flow temperature adjustment range (default setting: 75 °C)

Maximum permissible pressure

ENERGY 12r -A (H-

GB)

10 … 80 ℃

Nominal water flow (ΔT = 20 K)


Approximate value for the condensate volume (pH value between 3.5 and 4.0) at 50/30 °C

0.3 MPa

(3.0 bar)

530 l/h

353 l/h

1.23 l/h


GB)

10 … 80 ℃


GB)

10 … 80 ℃


GB)

10 … 80 ℃

0.3 MPa

(3.0 bar)

655 l/h

436 l/h

1.53 l/h

0.3 MPa

(3.0 bar)

788 l/h

525 l/h

1.84 l/h

0.3 MPa

(3.0 bar)

1,094 l/h

729 l/h

2.55 l/h


GB)

10 … 80 ℃

Max. flow temperature adjustment range (default setting: 75 °C)

Maximum permissible pressure



Approximate value for the condensate volume (pH value between 3.5 and 4.0) at 50/30 °C

0.3 MPa

(3.0 bar)

1,313 l/h

876 l/h

3.06 l/h

Technical data – G20 power/loading G20

Maximum heat output

Effective output range (P) at 40/30 °C



Domestic hot water heat output (P)

Maximum heat input –

heating (Q max.)

Minimum heat input – heat-

ing (Q min.)

Maximum heat input – hot

water (Q max.)

Minimum heat input – hot

water (Q min.)


GB)

12 kW

4.8 … 13.0 kW

4.7 … 12.8 kW

4.5 … 12.3 kW

4.4 … 15.0 kW

12.3 kW

4.5 kW

15.3 kW

4.5 kW


GB)

15 kW

4.8 … 16.2 kW

4.7 … 15.9 kW

4.5 … 15.2 kW

4.4 … 18.0 kW

15.3 kW

4.5 kW

18.4 kW

4.5 kW


GB)

18 kW

5.3 … 19.5 kW


GB)

25 kW

6.5 … 27.0 kW

5.2 … 19.1 kW

5.0 … 18.3 kW

4.9 … 25.2 kW

18.4 kW

5.0 kW

25.7 kW

5.0 kW

6.4 … 26.5 kW

6.1 … 25.4 kW

6.0 … 30.0 kW

25.5 kW

6.1 kW

30.6 kW

6.1 kW


GB)

30 kW

7.6 … 32.4 kW

Maximum heat output




Domestic hot water heat output (P)

7.4 … 31.8 kW

7.1 … 30.5 kW

7.0 … 35.0 kW


39

Appendix

Maximum heat input –

heating (Q max.)

Minimum heat input – heat-

ing (Q min.)

Maximum heat input – hot

water (Q max.)

Minimum heat input – hot

water (Q min.)


GB)

30.6 kW

7.1 kW

35.7 kW

7.1 kW

Technical data – General

Gas category

Diameter of the gas pipe


GB)

I

2H

1/2 inch


GB)

I

2H

1/2 inch


GB)

I

2H

1/2 inch


GB)

I

2H

1/2 inch

Diameter of the heating connections

3/4 inch

Expansion relief valve connector

(min.)

15 mm

Condensate drain pipework (min.)

21.5 mm

G20 gas supply pressure

2.0 kPa

1.6 m³/h Gas flow at P max. – hot water

(G20)

Gas flow at P max. – heating mode

(G20)

Gas flow at P min. (G20)

1.3 m³/h

CE number (PIN)

0.480 m³/h

CE-0063CP3646

2.08 g/s

Flue gas mass rate in heating mode at P min.

Flue gas mass rate in heating mode at P max.

Flue gas mass rate in hot water handling mode at P max.

Flue gas temperature (80 °C/60 °C) at P max.

Flue gas temperature (80 °C/60 °C) at P min.



Flue gas temperature in hot water handling mode

Flue gas temperature when overheating

Released system types

Nominal efficiency at 80/60 °C



5.5 g/s

6.9 g/s

55 ℃

55 ℃

43 ℃

32 ℃

71 ℃

105 ℃

C13, C33, C43, C53

99.6 %

104.0 %

106.0 %

3/4 inch

15 mm

21.5 mm

2.0 kPa

1.9 m³/h

1.6 m³/h

0.480 m³/h

CE-0063CP3646

2.08 g/s

6.9 g/s

8.3 g/s

55 ℃

55 ℃

48 ℃

32 ℃

71 ℃

105 ℃

C13, C33, C43, C53

99.6 %

104.0 %

106.0 %

3/4 inch

15 mm

21.5 mm

2.0 kPa

2.7 m³/h

1.9 m³/h

0.533 m³/h

CE-0063CP3646

2.31 g/s

8.3 g/s

11.6 g/s

60 ℃

55 ℃

51 ℃

34 ℃

69 ℃

105 ℃

C13, C33, C43, C53

99.6 %

104.0 %

106.0 %

3/4 inch

15 mm

21.5 mm

2.0 kPa

3.2 m³/h

2.7 m³/h

0.648 m³/h

CE-0063CP3646

2.81 g/s

11.5 g/s

13.8 g/s

77 ℃

55 ℃

62 ℃

35 ℃

68 ℃

95 ℃

C13, C33, C43, C53

99.6 %

104.0 %

106.0 %

108.5 % 108.5 % 108.5 % 108.5 %

Nominal efficiency in partial load operation (30%) at 40/30 °C

NOx class

Product dimensions, width

Product dimensions, depth

Product dimensions, height

5

375 mm

280 mm

600 mm

5

375 mm

280 mm

600 mm

5

375 mm

280 mm

600 mm

5

375 mm

280 mm

600 mm

40


Appendix

Net weight

Weight when filled with water


GB)

22 kg

26 kg

Gas category

Diameter of the gas pipe


GB)

I

2H

1/2 inch

Diameter of the heating connections

Expansion relief valve connector

(min.)

3/4 inch

15 mm

Condensate drain pipework (min.)

21.5 mm

G20 gas supply pressure

2.0 kPa

3.8 m³/h Gas flow at P max. – hot water

(G20)

Gas flow at P max. – heating mode

(G20)

Gas flow at P min. (G20)

CE number (PIN)

3.2 m³/h

0.756 m³/h

CE-0063CP3646

3.27 g/s

Flue gas mass rate in heating mode at P min.

Flue gas mass rate in heating mode at P max.

Flue gas mass rate in hot water handling mode at P max.





Flue gas temperature in hot water handling mode

Flue gas temperature when overheating

Released system types




Nominal efficiency in partial load operation (30%) at 40/30 °C

NOx class

13.8 g/s

16.1 g/s

86 ℃

56 ℃

60 ℃

37 ℃

75 ℃

104 ℃

C13, C33, C43, C53

99.6 %

104.0 %

106.0 %

108.5 %

Product dimensions, width

Product dimensions, depth

Product dimensions, height

Net weight

Weight when filled with water

5

375 mm

280 mm

600 mm

22 kg

27 kg


GB)

22 kg

26 kg


GB)

22 kg

26 kg


GB)

22 kg

26 kg


41

Appendix

Technical data – Electrics

Electric connection

Built-in fuse (slow-blow)

Max. electrical power consumption

Standby electrical power consumption

Level of protection

Electric connection

Built-in fuse (slow-blow)

Max. electrical power consumption

Standby electrical power consumption

Level of protection


GB)

230 V / 50 Hz

T2/2A, 250V

65 W


GB)

230 V / 50 Hz

T2/2A, 250V

65 W


GB)

230 V / 50 Hz

T2/2A, 250V

66 W


GB)

230 V / 50 Hz

T2/2A, 250V

75 W

2 W

IPX4D

2 W

IPX4D

2 W

IPX4D

2 W

IPX4D


GB)

230 V / 50 Hz

T2/2A, 250V

60 W

2 W

IPX4D

42


Index

Index

A

Air index setting................................................................... 18

Air/flue pipe ......................................................................... 12

Air/flue pipe, installed ............................................................ 4

Article number ....................................................................... 7

B

Burner anti-cycling time....................................................... 19

C

Calling up the fault memory................................................. 21

Carrying out

Gas family check ........................................................... 16

CE label................................................................................. 7

Check programmes ....................................................... 16, 24

Checking the burner ............................................................ 21

Checking the CO₂ content ................................................... 18

Cleaning the condensate siphon ......................................... 21

Cleaning the heat exchanger .............................................. 20

Combustion air ...................................................................... 4

Completing inspection work ................................................ 21

Completing maintenance work ............................................ 21

Completing repair work ....................................................... 23

Completing, repair work ...................................................... 23

Condensate drain pipework................................................. 12

Controller............................................................................. 15

Corrosion............................................................................... 4

D

Decommissioning ................................................................ 23

Decommissioning the product ............................................. 23

Diagnostics codes ............................................................... 15

Documents ............................................................................ 7

Draining the product ............................................................ 21

E

Electricity ............................................................................... 4

F

Fault codes.......................................................................... 21

Filling the condensate siphon.............................................. 17

Flue gas route ....................................................................... 4

Front casing, closed .............................................................. 4

Frost ...................................................................................... 5

G

Gas family check

Carrying out ................................................................... 16

I

H

Handing over to the operator............................................... 19

Identification plate ................................................................. 7

If you smell gas ..................................................................... 3

Inspection work ............................................................. 19, 24

Installation site....................................................................... 4

Installing the front casing..................................................... 10

Installing the side section .................................................... 10

Intended use.......................................................................... 3

M

Mains connection ................................................................ 14

Maintenance work ......................................................... 19, 24

Minimum clearance ............................................................... 9

P

Power supply....................................................................... 14

Preparing the repair work .................................................... 22

Preparing, repair work ......................................................... 22

R

Regulations ........................................................................... 5

Removing the air intake pipe............................................... 20

Removing the burner........................................................... 20

Removing the flue pipe........................................................ 20

Removing the gas-air mixture unit....................................... 20

Removing the side section .................................................. 10

Replacing the burner ........................................................... 22

Replacing the heat exchanger............................................. 22

Replacing the main PCB ..................................................... 23

Resetting the burner anti-cycling time ................................. 19

S

Safety device......................................................................... 4

Schematic drawing ................................................................ 4

Serial number ........................................................................ 7

Setting the burner anti-cycling time ..................................... 19

Setting the CO₂ content....................................................... 18

Spare parts.......................................................................... 19

Supply of combustion air ....................................................... 4

Switching on the product ..................................................... 17

T

Tool ....................................................................................... 5

Transport ............................................................................... 3

Transporting .......................................................................... 8

Treating the heating water .................................................. 16

U

Unloading the box ................................................................. 8

Unpacking the product .......................................................... 8

User interface, replacing the PCB ....................................... 23

V

Voltage .................................................................................. 4

W

Wall-mounting the product .................................................... 9

Weight ................................................................................... 9


43

Publisher/manufacturer

Glow-worm

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 016 34 29 23 00 ‒ Fax 016 34 29 01 66

Technical helpline 084 4 736 00 59 ‒ After sales service 017 73 82 81 00 www.glow-worm.co.uk

0020177748

We reserve the right to make technical changes.

The energy you need

0020177748_00 - 16.06.2015 11:23:47

Glow-worm ENERGY 12r -A (H-GB), 15r -A (H-GB), 18r -A (H-GB), 25r -A (H-GB), 30r -A (H-GB) water heaters & boilers Installation and maintenance instructions

Assistant Bot

The energy you need

Installation and maintenance instructions

ENERGY ..r

ENERGY 12r -A (H-GB)

ENERGY 15r -A (H-GB)

ENERGY 18r -A (H-GB)

ENERGY 25r -A (H-GB)

ENERGY 30r -A (H-GB)

Contents

1 Safety

1.1

Action-related warnings

Classification of action-related warnings

Warning symbols and signal words

Danger!

Danger!

Warning.

Caution.

1.2

Intended use

Caution.

1.3

General safety information

1.3.1 Required personnel qualifications

1.3.2 Risk of injury during transport due to a high product weight.

1.3.3 Risk of death from escaping gas

1.3.4 Risk of death from escaping flue gas

1.3.5 Risk of death due to blocked or leaking flue gas routes

1.3.6 Risk of poisoning and burns caused by escaping hot flue gases

1.3.7 Risk of death due to explosive and flammable materials

1.3.8 Risk of death from electric shock

1.3.9 Risk of death due to lack of safety devices

1.3.10 Risk of poisoning caused by insufficient supply of combustion air

Conditions: Open-flued operation

1.3.11 Risk of death due to cabinet-type casing

1.3.12 Risk of corrosion damage due to unsuitable combustion and room air

1.3.13 Risk of material damage caused by frost

1.3.14 Risk of being burned or scalded by hot components

1.3.15 Risk of material damage caused by using an unsuitable tool

1.4

Regulations (directives, laws, standards)

Employers and installers should refer to the HSE web site for full advice and manual handling assessment charts

(MAC) tool.

2

Notes on the documentation

3 Product description

4 Installation

5 Installation

6 Operation

7

Start-up

8 Adapting the unit to the heating installation

9 Handing the product over to the operator

10 Inspection and maintenance

11 Troubleshooting

12 Decommissioning the product

13 Customer service

Appendix

A

Inspection and maintenance work – Overview

B

Check programmes – Overview

C Overview of diagnostics codes

D

Status codes – Overview

E Overview of fault codes

F Connection diagram

G Connection diagram, 30 kW

H Opening in the flue pipe

I Commissioning Checklist

Benchmark Commissioning and

Servicing Section

www.centralheating.co.uk

J Combustion chart

K Technical data

Index

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Key Features