WarmFlow GS25A, Manual

Page 1: ...Instructions Installation Instructions Commissioning Instructions Maintenance Instructions Commissioning Certificate Service Record High Efficiency Condensing Gas Boilers Model covered by this manual...

Page 2: ...TR05A140 B1107...

Page 3: ...15 4 2 Unpacking 16 4 3 Installing the boiler 17 4 3 1 Compartment ventilation 17 4 4 Water connections 18 4 4 1 Central heating circuit 19 4 4 2 Filling the central heating system 19 4 5 Condensate...

Page 4: ...5 6 6 Maintenance operations 46 6 6 1 Primary heat exchanger and burner unit 47 6 6 2 Ignition and ionisation electrodes 48 6 6 3 Safety thermostat 48 6 6 4 Heating sensor 48 6 6 5 Gas valve 49 6 6 6...

Page 5: ...7 Digital LCD display 8 Programmer location N A 1 1 2 Operating the appliance Operation Instruction Switching the boiler on Press the ON OFF button 1 Adjusting the Central Heating temperature Turn the...

Page 6: ...n using the ON OFF button on the Control Panel Check that Error Code H2O is no longer shown on the Control Panel display Close the filling loop valve or valves and disconnect the filling loop The boil...

Page 7: ...roduct and must be kept with the appliance in a safe place available for future reference This manual along with the Benchmark commissioning booklet must be left with the end user as per Regulation 29...

Page 8: ...ed to an effective earth system installed in accordance with the requirements of current safety standards This fundamental safety requirement must be checked and verified In case of doubt have the ele...

Page 9: ...LOW VOLTAGE DIRECTIVE 73 23 CEE ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 89 336 CEE BOILER EFFICIENCY DIRECTIVE 92 42 CEE UNI EN 297 for GAS FIRED CENTRAL HEATING BOILERS TYPE B OF NOMINAL HEAT INPUT 7...

Page 10: ...r 2 5 Min CH working pressure bar 0 3 Dimensions Width mm 410 Height mm 730 Depth mm 285 Weight net kg 46 Hydraulic Connections CH Flow connection 3 4 22mm tail supplied CH Return connection 3 4 22mm...

Page 11: ...A140 B1107 9 110 137 163 285 132 730 HF G HR 148 49 182 31 285 730 111 5 187 111 5 48 5 313 48 5 105 ON OFF 3 2 Dimensions LEGEND HR HEATING RETURN 22mm HF HEATING FLOW 22mm G GAS 22mm SC CONDENSATE D...

Page 12: ...ELIEF VALVE HEATING CIRCUIT 11 AUTOMATIC AIR VENT VALVE 12 HEATING SAFETY THERMOSTAT 13 HEATING SENSOR 14 PUMP WITH AIR VENT 15 WATER PRESSURE SWITCH 16 FLUE HOOD 17 FLUE SAFETY THERMOFUSE 18 EXPANSIO...

Page 13: ...EF VALVE HEATING CIRCUIT 11 AUTOMATIC AIR VENT VALVE 12 HEATING SAFETY THERMOSTAT 13 HEATING SENSOR 14 PUMP WITH AIR VENT 15 WATER PRESSURE SWITCH 16 FLUE HOOD 17 FLUE SAFETY THERMOFUSE 18 EXPANSION V...

Page 14: ...mp performance curves Figure 5 Pump performance curves I II I II III 1400 1200 1600 70 50 60 40 1000 800 400 600 30 10 20 0 0 200 III Appliance Loss Available head at minimum speed Available head at s...

Page 15: ...tton 5 MODE button 6 Mains supply terminal board 7 Digital LCD display 8 Programmer location N A 3 6 2 Boiler operation Mode Control Input Display will show Boiler switched off OFF Press ON OFF button...

Page 16: ...ut for 15 minutes without modulation Activated by pressing and holding the S button for 7 seconds Deactivated by switching the appliance off 08 CH Frost Protection Mode Operates the boiler at minimum...

Page 17: ...de of Practice In the United Kingdom the following Codes of Practice apply BS 5440 Part 1 Flues BS 5440 Part 2 Air Supply BS 5546 Installation of hot water supplies for domestic purposes BS 5449 Force...

Page 18: ...eft within reach of children in that these items represent a potential hazard A With the packed appliance on the floor see Figure 7 remove the staples and open out the four flaps on the end of the box...

Page 19: ...boiler is supplied with a template to enable the pipe connections to be positioned prior to fixing the appliance to the wall To install the boiler proceed as follows see Figure 9 1 Use a spirit level...

Page 20: ...table for this purpose Isolation valves must be installed on the CH circuit in order to facilitate all maintenance and service operations where the boiler needs to be drained The boiler is supplied wi...

Page 21: ...stem bypass is fitted Lockshield valve Mains water inlet Pressure reducing valve reccomended for inlet supplies in excess pf 3 5 bar DHW outlet Filling point see fig 2 Radiator valve Note A drain tap...

Page 22: ...garage must be insulated to protect against frost It is also recommended that the pipe diameter is increased to 32mm Any pipe run external to the building must not exceed 3 metres in length If the bo...

Page 23: ...l devices required by current standards The gas supply line must be a minimum of a 22 mm diameter pipe with a direct supply from meter to boiler and comply with current standards and regulations Check...

Page 24: ...th system The boiler is designed to operate with a 230 V 50 Hz supply The connection to the mains electricity supply must be via a fused spur and the appliance must be protected by a 3A fuse Make sure...

Page 25: ...ermanent live wire coloured brown to the terminal marked with the letter L e Replace terminal block cover A The appliance MUST be supplied with a permanent live in order for the boiler s protective fu...

Page 26: ...bustion chamber which has been specifically designed to collect and drain the acidic condensate For the air intake duct of a twin pipe system the entire length of the duct must slope downwards towards...

Page 27: ...ur the appliance MUST BE TURNED OFF IMMEDIATELY Where the lowest part of the terminal is fitted less than 2m 6 6ft above a balcony above ground or above a flat roof to which people have access the ter...

Page 28: ...Y 60 100 MAXIMUM FLUE LENGTH 5 m The flue length is the total length of the flue excluding the first bend The total length is calculated by summing the lengths of all the straight section AND the equi...

Page 29: ...MAXIMUM FLUE LENGTH 7 m The flue length is the total length of the flue excluding the first bend The total length is calculated by summing the lengths of all the straight section AND the equivalent l...

Page 30: ...ONLY 60 100 MAXIMUM FLUE LENGTH 5 m The flue length is the total length of the flue excluding the first bend The total length is calculated by summing the lengths of all the straight section AND the...

Page 31: ...125 MAXIMUM FLUE LENGTH 7 m The flue length is the total length of the flue excluding the first bend The total length is calculated by summing the lengths of all the straight section AND the equivale...

Page 32: ...ILERS ONLY 80 80 MAXIMUM FLUE LENGTH 50 m The flue length is the total length of both the intake and exhaust sections excluding the first bend of each The total length is calculated by summing the len...

Page 33: ...l and earth wires are correctly connected Also that the earth connection is sound and that the appliance is effectively earthed That the gas supply is correctly sized for the flow rate required by the...

Page 34: ...rew the manual air vent valve located in the top left hand corner of the primary heat exchanger until air begins to escape When water begins to flow out screw the valve tightly closed Open the air ven...

Page 35: ...each radiator on the system in turn open the radiator valves allowing water to flow through then turn that radiator off Repeat for all the radiators on the system e Close the drain cock re open all r...

Page 36: ...minutes then reset the appliance by switching the boiler off then on using the ON OFF button on the Control Panel With the boiler ignited if the system still emits noises the above process must be rep...

Page 37: ...CH delay timer 00 90 default 36 Expressed in steps of 5 seconds Default 36 x 5 sec 180 sec 7 CH pump overrun timer 00 90 default 36 Expressed in steps of 5 seconds Default 36 x 5 sec 180 sec 8 Not ap...

Page 38: ...the buttons Switch the appliance on using the ON OFF button Release the buttons Step 3 Press and hold the S button Use the button to cycle up through the parameters Step 4 Release the S button Press...

Page 39: ...menu as described in Section 5 7 1 Use the buttons to adjust the parameter value 00 Natural gas Methane 01 LPG Press and release the S button The parameter number 2 will appear on the display To store...

Page 40: ...Use the buttons to adjust the parameter value 00 0 x 5 seconds 0 seconds minimum 90 90 x 5 seconds 450 seconds maximum Note Factory preset to 36 180 seconds Press and release the S button The paramete...

Page 41: ...se the buttons to adjust the parameter value 00 Atmospheric burner all outputs 01 Premix burner 25 kW 02 Premix burner 29 34 kW 03 Premix burner 50 kW Press and release the S button The parameter numb...

Page 42: ...ay To store your changes switch the appliance off then on again using the ON OFF button Parameter 19 Minimum fan speed in CH mode Access the parameters menu as described in Section 5 7 1 Use the butto...

Page 43: ...he S button The parameter number 21 will appear on the display To store your changes switch the appliance off then on again using the ON OFF button Parameter 22 Fan speed display mode Access the param...

Page 44: ...9 LPG Propane G31 60 149 Table 8 Reference fan speeds Natural Gas G20 Liquid Butane Gas G30 Liquid Propane Gas G31 Lower Wobbe index 15 C 1013 mbar MJ Nm 3 45 67 80 58 70 69 Nominal Supply Pressure mb...

Page 45: ...seal of the room sealed chamber is undamaged and positioned correctly The condition of the primary heat exchanger clean if necessary The maximum and minimum modulation fan speeds and the modulation pr...

Page 46: ...y be removed after the front panel has been removed Remove the fixing screws at the front and lower edge of the side panel Grasp the bottom of the panel move it sideways and then upwards see Figure 34...

Page 47: ...e highest and moving down the system to the lowest When the system has been drained close the radiator air vents and the boiler drain valve If ONLY THE BOILER needs to be drained Switch on the boiler...

Page 48: ...sible for damage to any of the boiler s components caused by non compliance with this instruction Section 6 3 gives instructions on accessing the boiler removing casing panels and accessing the contro...

Page 49: ...ectrodes carefully without altering their positions with respect to the burner Clean the burner cylinder using a non metal brush and without damaging the ceramic fibre Check the integrity of the seal...

Page 50: ...h a 10mm gap between it and the burner The ionisation electrode must not be touching the burner surface 6 6 3 Safety thermostat Isolate the electricity water and gas supplies to the appliance Disconne...

Page 51: ...eak detector spray Switch on the electricity and water supplies switch on and fire the appliance and repeat the checks for leaks 6 6 6 Circulating pump motor body Isolate the electricity water and gas...

Page 52: ...the above procedure in reverse order Switch on the electricity water and gas supplies and check the soundness of the joint by measuring the CO2 levels 6 6 8 Expansion vessel Isolate the electricity w...

Page 53: ...oard Replace the circuit board and reassemble the components following the above procedure in reverse order 6 6 11 Primary heat exchanger replacement Isolate the electricity water and gas supplies to...

Page 54: ...RG128 1300 3612 N L yellow green fusibile 2A brown light blue brown orange orange light blue light blue brown white black black orange orange brown brown brown black black light blue orange red light...

Page 55: ...TED b THERMOFUSE LOCK OUT DUE TO HIGH FLUE TEMPERATURE c THERMOFUSE MALFUNCTION a CHECK THERMOSTAT WIRING b REPLACE THERMOSFUSE RESTART AND CHECK APPLIANCE c REPLACE PART H20 LOW SYSTEM PRESSURE a WAT...

Page 56: ...4 WASHER OR CLIPS KIT FOR MULTIPLEX 28590015 WATER PRESSURE SWITCH PC 5411 BRASS 40735016 HTG CLIP SENSOR X PIPE 17 18 mm BLUE 40735017 THERMO FUSE 102 C RED ISTMQ 1 4 4X45 16766077 PRINTED CIRCUIT BO...

Page 57: ...programmer room thermostat or other external controls Isolate the electricity water and gas supplies to the appliance Remove the front casing panel of the boiler refer to 6 3 for guidance Remove termi...

Page 58: ...tic Zero volt Switching Circuit Add more valves programmers as required Permanent Live Boiler Terminal Block Heating Zone Hot Water Cylinder Cylinder Thermostat Room Thermostat 2 port zone valves Zone...

Page 59: ...THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK...

Page 60: ...THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK...

Page 61: ...Make Model Serial No SEDBUK Efficiency Location New System or Replacement boiler Controls To comply with Building Regulations each section must have a tick in one or more boxes Requirement Measures Pr...

Page 62: ...mum Burner Operating Pressure mbar Maximum Operating Water Pressure bar Cold Water Inlet Temperature C Hot Water Outlet Temperature C Water Flow Rate at Maximum Setting l min For Condensing Boilers On...

Page 63: ...No Comments Comments Signature Signature Service 5 Date Service 6 Date Engineer Name Engineer Name Company Name Company Name Tel No Tel No CORGI ID Serial No CORGI ID Serial No Comments Comments Sign...

Page 64: ...THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK...

Page 65: ...THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK...

Page 66: ...AND ARE NOT BINDING THE COMPANY RESERVES THE RIGHT TO APPLY VARIATIONS WITHOUT PRIOR NOTIFICATION NEITHER WILL THE COMPANY BE HELD RESPONSIBLE FOR ANY INACCURACIES IN THIS HANDBOOK DERIVING FROM PRIN...