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Installation and main- tenance instructions ENERGY 25c 30c 35c GB, IE

Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

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Page 1: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Installation and main-tenance instructionsENERGY

25c

30c

35c

GB IE

Contents

2 Installation and maintenance instructions ENERGY 0020177746_03

Contents

1 Safety 4

11 Action-related warnings 4

12 Risk caused by inadequate qualifications 4

13 Intended use 4

14 General safety information 4

15 Regulations (directives laws standards) 6

2 Notes on the documentation 7

21 Observing other applicable documents 7

22 Storing documents 7

23 Validity of the instructions 7

24 Benchmark 7

3 Product description 7

31 Compartment Ventilation 7

32 Information on the identification plate 7

33 Functional elements Combination unit 8

34 CE label 8

4 Set-up 8

41 Transporting the unit 8

42 Unpacking the product 8

43 Checking the scope of delivery 8

44 Dimensions 9

45 Minimum clearances 9

46 Using the mounting template 9

47 Wall-mounting the product 9

48 Removinginstalling the front casing 10

49 Removinginstalling the side section 10

5 Installation 11

51 Checking the gas meter 11

52 Gas and water connections 11

53 Connecting the drain pipework for theexpansion relief valve 12

54 Connecting the condensate discharge pipe 12

55 Electrical installation 13

6 Operation 15

61 Using diagnostics codes 15

62 Displaying the status codes 15

63 Using check programmes 16

7 Start-up 16

71 Carrying out the initial start-up 16

72 Checking the type of gas 16

73 Checking the factory setting 16

74 Checking and treating the heating waterfillingand supplementary water 16

75 Avoiding danger arising from insufficient waterpressure 17

76 Switching on the product 18

77 Filling and purging the heating installation 18

78 Filling the condensate siphon 18

79 Filling the hot water circuit 18

710 Checking and adjusting the gas settings 18

711 Checking leak-tightness 20

8 Adapting the unit to the heatinginstallation 21

81 Burner anti-cycling time 21

82 Setting the pump output 21

83 Setting the bypass valve 22

84 Setting the hot water temperature 22

9 Handing the product over to the end user 22

10 Inspection and maintenance 22

101 Using original seals 22

102 Observing inspection and maintenanceintervals 22

103 Procuring spare parts 23

104 Checking the CO₂ content 23

105 Setting the CO₂ content 23

106 Removing the gas-air mixture unit 24

107 Cleaning the heat exchanger 24

108 Checking the burner 25

109 Checking the ignition electrode 25

1010 Cleaning the condensate siphon 25

1011 Cleaning the filter in the cold water inlet 25

1012 Cleaning the heating filter 25

1013 Installing the gas-air mixture unit 26

1014 Draining the product 26

1015 Checking the admission pressure of theexpansion vessel 26

1016 Completing inspection and maintenance work 26

1017 Checking the product for leak-tightness 26

11 Troubleshooting 26

111 Rectifying faults 26

112 Calling up the fault memory 26

113 Deleting the fault memory 26

114 Resetting parameters to factory settings 26

115 Preparing the repair work 26

116 Replacing defective components 26

117 Checking the product for leak-tightness 29

12 Decommissioning the product 29

13 Customer service 29

Appendix 30

A Check programmes ndash Overview 30

B Overview of diagnostics codes 30

C Status codes ndash Overview 34

D Overview of fault codes 35

E Wiring diagram Combi boiler 37

F Wiring diagram Combi boiler (35 kW) 38

G Inspection and maintenance work ndashOverview 39

H Position of the opening in the airflue pipe 40

H1 Positioning of the opening of a fan-supportedflue gas pipe 40

H2 Horizontal terminal positioning 41

I Commissioning Checklist 42

Contents

0020177746_03 ENERGY Installation and maintenance instructions 3

J Pipe lengths for the airflue pipe 46

J1 Length of the C13 type airflue pipe 46

J2 Length of the C33 type airflue pipe 46

J3 Length of the C43 type airflue pipe 46

K Technical data 46

Index 49

1 Safety

4 Installation and maintenance instructions ENERGY 0020177746_03

1 Safety

11 Action-related warnings

Classification of action-related warningsThe action-related warnings are classified inaccordance with the severity of the possibledanger using the following warning signs andsignal words

Warning symbols and signal wordsDangerImminent danger to life or risk ofsevere personal injury

DangerRisk of death from electric shock

WarningRisk of minor personal injury

CautionRisk of material or environmentaldamage

12 Risk caused by inadequatequalifications

ndash Set-upndash Dismantlingndash Installationndash Start-upndash Inspection and maintenancendash Repairndash Decommissioning

Observe all instructions that are includedwith the product

Proceed in accordance with current tech-nology

Observe all applicable directives stand-ards laws and other regulations

13 Intended use

There is a risk of injury or death to the user orothers or of damage to the product and otherproperty in the event of improper use or usefor which it is not intended

The product is intended as a heat generatorfor closed heating installations and for hotwater generation

Depending on the unit type the productsreferred to in these instructions must only beinstalled and operated in conjunction with the

airflue pipe accessories listed in the otherapplicable documents

Intended use includes the following

ndash observance of accompanying operatinginstallation and servicing instructions forthe product and any other system compon-ents

ndash installing and fitting the product in accord-ance with the product and system approval

ndash compliance with all inspection and main-tenance conditions listed in the instruc-tions

Intended use also covers installation in ac-cordance with the IP code

Any other use that is not specified in these in-structions or use beyond that specified in thisdocument shall be considered improper useAny direct use in industrial or commercialprocesses is also deemed to be improper

Caution

Improper use of any kind is prohibited

14 General safety information

141 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 (eg lighters

matches) Do not smoke Do not use any electrical switches mains

plugs doorbells telephones or other com-munication systems in the building

If it is safe to do so close the emergencycontrol valve or the main isolator

If possible close the gas isolator cock onthe product

Warn other occupants in the building byyelling or banging on doors or walls

Leave the building immediately and ensurethat others do not enter the building

Notify the gas supply company or the Na-tional Grid +44 (0) 800 111999 by tele-phone once you are outside of the build-ing

Safety 1

0020177746_03 ENERGY Installation and maintenance instructions 5

142 Risk of death from escaping fluegas

If you operate the product with an empty con-densate trap siphon then flue gas may es-cape into the room air

In order to operate the product ensure thatthe condensate trap siphon is always full

143 Risk of death due to blocked orleaking flue gas routes

Installation errors damage tampering unau-thorised installation sites or similar can causeflue gas to escape and result in a risk of pois-oning

What to do if you smell flue gas in the prop-erty

Open all accessible doors and windowsfully to provide ventilation

Switch off the product Check the flue gas routes in the product

and the flue gas diversions

144 Risk of death due to explosive andflammable materials

Do not use the product in storage roomsthat contain explosive or flammable sub-stances (such as petrol paper or paint)

145 Risk of death from electric shock

There is a risk of death from electric shock ifyou touch live components

Before commencing work on the product

Unplug the mains plug Or disconnect the product from the power

supply by switching off all power supplies(electrical partition with a contact gap of atleast 3 mm eg fuse or circuit breaker)

Secure against being switched back onagain

Wait for at least 3 minutes until the capa-citors have discharged

Check that there is no voltage

146 Risk of death due to lack of safetydevices

The schematic drawings included in this doc-ument do not show all safety devices re-quired for correct installation

Install the necessary safety devices in thesystem

Observe the applicable national and inter-national laws standards and guidelines

147 Risk of poisoning and burns causedby escaping hot flue gases

Only operate the product if the airflue pipehas been completely installed

With the exception of short periods fortesting purposes only operate the productwhen the front casing is installed andclosed

148 Risk of being burned or scalded byhot components

Only carry out work on these componentsonce they have cooled down

149 Risk of injury due to the heavyweight of the product

Make sure that the product is transportedby at least two people

1410 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the fluesystem

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similarlocations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1411 Risk of material damage caused byfrost

Do not install the product in rooms proneto frost

1 Safety

6 Installation and maintenance instructions ENERGY 0020177746_03

1412 Risk of material damage caused byusing an unsuitable tool

Use the correct tool to tighten or loosenthreaded connections

15 Regulations (directives lawsstandards)

Observe the national regulations stand-ards guidelines and laws

Notes on the documentation 2

0020177746_03 ENERGY Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Validity of the instructions

These instructions apply only to

Product article number

Article number Gas CouncilNumber

ENERGY 25c -A (H-GB)

0010015652 47-019-24

ENERGY 30c -A (H-GB)

0010015653 47-019-25

ENERGY 35c -A (H-GB)

0010015654 47-019-26

24 Benchmark

Glow-worm is a licensed member of the BenchmarkScheme

Benchmark places responsibilities on both manufacturersand installers The purpose is to ensure that customers areprovided with the correct equipment for their needs that it isinstalled commissioned and serviced in accordance with themanufacturerrsquos instructions by a competent person approvedat the time by the Health and Safety Executive and that itmeets the requirements of the appropriate Building Regu-lations The Benchmark Checklist can be used to demon-strate compliance with Building Regulations and should beprovided to the customer for future reference

Installers are required to carry out installation commission-ing and servicing work in accordance with the BenchmarkCode of Practice which is available from the Heating andHotwater Industry Council who manage and promote theScheme

Benchmark is managed and promoted by the Heating andHotwater Industry Council

For more information visit wwwcentralheatingcouk

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

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

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

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

For identification purposes 7th to 16thdigits = product article number

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

ENERGY c Product description

2H G20 ndash 20 kPa(20 mbar)

Factory setting for type of gas and gasconnection pressure

Cat Approved gas category

Condensing techno-logy

Efficiency class of the boiler in accord-ance with EC Directive 9242EEC

Type Xx3(x) Permissible flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

4 Set-up

8 Installation and maintenance instructions ENERGY 0020177746_03

Information on theidentification plate

Meaning

Read the instructions

GC no Gas council number

33 Functional elements Combination unit

15

12

11

10

8

9

7

5

6

4

3

2

1

18

17

20 19

14

16

13

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Condensate siphon

5 Flue gas pipe

6 Pressure sensor

7 Flue gas analysis point(for rear flue gas con-nection)

8 Ignition transformer

9 Gas valve

10 Air intake pipe

11 Fan

12 Supply air measuringstub pipe (for upper fluegas connection)

13 Flue gas analysis point(for upper flue gasconnection)

14 Primary heat exchanger

15 Heating expansionvessel

16 Purge hose

17 Volume flow sensor

18 Heating pump

19 Bypass

20 3-way valve

34 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend 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 yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete and intact

Number Designation

1 Heat generator

1 Unit mounting bracket

1 Flexible condensate discharge pipe

6 34 seals

4 12 seals

1 Service valve

1 Gas stopcock

1 Filling device

Set-up 4

0020177746_03 ENERGY Installation and maintenance instructions 9

Number Designation

2 Connection pipe (heating flow and return)

1 Cold water connection pipe

1 Domestic hot water connection pipe

1 Gas pipe

1 Expansion relief valve discharge pipe

1 Mounting template

1 Enclosed documentation

44 Dimensions

96121

34

123185

390

12358 58

170

702

150

280

1 2 3 4 5

7

6

1 Heating flow

2 Hot water connection

3 Gas connection

4 Cold water connection

5 Heating return

6 Connection on the backof the airflue pipe

7 Connection on the topof the airflue pipe

45 Minimum clearances

CC

AB

D

Minimum clearance

A 150 mm (top airflue gas connection)

20 mm (airflue gas connection on the rear)

B 150 mm

C 5 mm

(70 mm if the side panels ought to be removed)

D 600 mm

It is not necessary to maintain a clearance between theproduct and components made of combustible materials thatgo beyond the minimum clearances

46 Using the mounting template

Use the mounting template to ascertain the locations atwhich you need to drill holes

47 Wall-mounting the product

Note

If you are using the rear airflue gas connectioninstall the airflue pipe before you wall-mount theproduct

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the operational weight of the product

2 Check if the supplied fixing material may be used forthe wall

4 Set-up

10 Installation and maintenance instructions ENERGY 0020177746_03

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial 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 suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

Conditions The fixing material may not be used for the wall

Wall-mount the product as described using the permittedfixing material provided on-site

48 Removinginstalling the front casing

481 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

482 Installing the front casing

Refit the components in the reverse order

49 Removinginstalling the side section

491 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least70 mm) you can remove the side section to fa-cilitate maintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

492 Installing the side section

Refit the components in the reverse order

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 11

5 Installation

DangerRisk of scalding andor damage due toincorrect installation leading to escapingwater

Mechanical stresses in the connection pipesmay lead to leaks

Ensure that there is no mechanical stresswhen installing the connection pipes

CautionRisk of material damage caused byresidues in the pipelines

Welding remnants sealing residues dirt orother residues in the pipelines may damagethe product

Flush the heating installation thoroughlybefore installing the product

51 Checking the gas meter

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

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of material damage caused by corro-sion

Due to non-diffusion-tight plastic pipes in theheating installation air gets into the heatingwater Air in the heating water causes corro-sion in the heat generator circuit and in theproduct

If you use non-diffusion-tight plastic pipesin the heating installation ensure that noair gets into the heat generator circuit

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connectors if the connectorsare not yet screwed to the service valves

Note

Apply heat insulation to the water pipes to theboiler outlet and to the installation

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the installation

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return valve at the products outlet(heating flow)

2 Ensure that the installation has the following compon-ents

ndash A cold water stopcock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas pipe before start-up

3 Check whether the connections (rarr Page 20) are leak-tight

5 Installation

12 Installation and maintenance instructions ENERGY 0020177746_03

53 Connecting the drain pipework for theexpansion relief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The piping must be installed in such a way that youcan see when water drips out

54 Connecting the condensate discharge pipe

1

2

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

Use PVC or any other material that is suitable for drain-ing the non-neutralised condensate

If you cannot guarantee that the materials from which thedrain pipework is made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate traps (1) Use the supplied drainhose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burrs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

For any installation the condensate must be free flowingand not be possible for air back-pressure to prevent wa-ter flow

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat input below 70 kW

541 Condensate drainage systems

5411 Internal soil and vent pipe

Oslash19mm min

5412 External soil and vent pipe

L = 3m max

Oslash19mm min

Oslash30mm

5413 External termination into a gulley or hopper

L = 3m max

Oslash19mm min

Oslash30mm

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 13

5414 Internal termination into combined sinkwaste

Oslash30mm

Oslash19mm min

5415 Internal termination downstream of sinkwaste

Oslash30mm

Oslash19mm min

5416 External termination into soakaway

400m

m m

in

300m

m m

in25

mm

min

500mm min

Oslash100mm

L = 3m max

Oslash19mm min

Oslash30mm

5417 External termination into rain water downpipe

Oslash19mm min

Oslash30mm

55 Electrical installation

DangerRisk of death from electric shock

The power supply terminals L and N remainlive even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

Only qualified electricians may carry out the electrical install-ation

551 Opening the electronics box

B

B

A

Follow the instructions in the specified sequence

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 2: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Contents

2 Installation and maintenance instructions ENERGY 0020177746_03

Contents

1 Safety 4

11 Action-related warnings 4

12 Risk caused by inadequate qualifications 4

13 Intended use 4

14 General safety information 4

15 Regulations (directives laws standards) 6

2 Notes on the documentation 7

21 Observing other applicable documents 7

22 Storing documents 7

23 Validity of the instructions 7

24 Benchmark 7

3 Product description 7

31 Compartment Ventilation 7

32 Information on the identification plate 7

33 Functional elements Combination unit 8

34 CE label 8

4 Set-up 8

41 Transporting the unit 8

42 Unpacking the product 8

43 Checking the scope of delivery 8

44 Dimensions 9

45 Minimum clearances 9

46 Using the mounting template 9

47 Wall-mounting the product 9

48 Removinginstalling the front casing 10

49 Removinginstalling the side section 10

5 Installation 11

51 Checking the gas meter 11

52 Gas and water connections 11

53 Connecting the drain pipework for theexpansion relief valve 12

54 Connecting the condensate discharge pipe 12

55 Electrical installation 13

6 Operation 15

61 Using diagnostics codes 15

62 Displaying the status codes 15

63 Using check programmes 16

7 Start-up 16

71 Carrying out the initial start-up 16

72 Checking the type of gas 16

73 Checking the factory setting 16

74 Checking and treating the heating waterfillingand supplementary water 16

75 Avoiding danger arising from insufficient waterpressure 17

76 Switching on the product 18

77 Filling and purging the heating installation 18

78 Filling the condensate siphon 18

79 Filling the hot water circuit 18

710 Checking and adjusting the gas settings 18

711 Checking leak-tightness 20

8 Adapting the unit to the heatinginstallation 21

81 Burner anti-cycling time 21

82 Setting the pump output 21

83 Setting the bypass valve 22

84 Setting the hot water temperature 22

9 Handing the product over to the end user 22

10 Inspection and maintenance 22

101 Using original seals 22

102 Observing inspection and maintenanceintervals 22

103 Procuring spare parts 23

104 Checking the CO₂ content 23

105 Setting the CO₂ content 23

106 Removing the gas-air mixture unit 24

107 Cleaning the heat exchanger 24

108 Checking the burner 25

109 Checking the ignition electrode 25

1010 Cleaning the condensate siphon 25

1011 Cleaning the filter in the cold water inlet 25

1012 Cleaning the heating filter 25

1013 Installing the gas-air mixture unit 26

1014 Draining the product 26

1015 Checking the admission pressure of theexpansion vessel 26

1016 Completing inspection and maintenance work 26

1017 Checking the product for leak-tightness 26

11 Troubleshooting 26

111 Rectifying faults 26

112 Calling up the fault memory 26

113 Deleting the fault memory 26

114 Resetting parameters to factory settings 26

115 Preparing the repair work 26

116 Replacing defective components 26

117 Checking the product for leak-tightness 29

12 Decommissioning the product 29

13 Customer service 29

Appendix 30

A Check programmes ndash Overview 30

B Overview of diagnostics codes 30

C Status codes ndash Overview 34

D Overview of fault codes 35

E Wiring diagram Combi boiler 37

F Wiring diagram Combi boiler (35 kW) 38

G Inspection and maintenance work ndashOverview 39

H Position of the opening in the airflue pipe 40

H1 Positioning of the opening of a fan-supportedflue gas pipe 40

H2 Horizontal terminal positioning 41

I Commissioning Checklist 42

Contents

0020177746_03 ENERGY Installation and maintenance instructions 3

J Pipe lengths for the airflue pipe 46

J1 Length of the C13 type airflue pipe 46

J2 Length of the C33 type airflue pipe 46

J3 Length of the C43 type airflue pipe 46

K Technical data 46

Index 49

1 Safety

4 Installation and maintenance instructions ENERGY 0020177746_03

1 Safety

11 Action-related warnings

Classification of action-related warningsThe action-related warnings are classified inaccordance with the severity of the possibledanger using the following warning signs andsignal words

Warning symbols and signal wordsDangerImminent danger to life or risk ofsevere personal injury

DangerRisk of death from electric shock

WarningRisk of minor personal injury

CautionRisk of material or environmentaldamage

12 Risk caused by inadequatequalifications

ndash Set-upndash Dismantlingndash Installationndash Start-upndash Inspection and maintenancendash Repairndash Decommissioning

Observe all instructions that are includedwith the product

Proceed in accordance with current tech-nology

Observe all applicable directives stand-ards laws and other regulations

13 Intended use

There is a risk of injury or death to the user orothers or of damage to the product and otherproperty in the event of improper use or usefor which it is not intended

The product is intended as a heat generatorfor closed heating installations and for hotwater generation

Depending on the unit type the productsreferred to in these instructions must only beinstalled and operated in conjunction with the

airflue pipe accessories listed in the otherapplicable documents

Intended use includes the following

ndash observance of accompanying operatinginstallation and servicing instructions forthe product and any other system compon-ents

ndash installing and fitting the product in accord-ance with the product and system approval

ndash compliance with all inspection and main-tenance conditions listed in the instruc-tions

Intended use also covers installation in ac-cordance with the IP code

Any other use that is not specified in these in-structions or use beyond that specified in thisdocument shall be considered improper useAny direct use in industrial or commercialprocesses is also deemed to be improper

Caution

Improper use of any kind is prohibited

14 General safety information

141 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 (eg lighters

matches) Do not smoke Do not use any electrical switches mains

plugs doorbells telephones or other com-munication systems in the building

If it is safe to do so close the emergencycontrol valve or the main isolator

If possible close the gas isolator cock onthe product

Warn other occupants in the building byyelling or banging on doors or walls

Leave the building immediately and ensurethat others do not enter the building

Notify the gas supply company or the Na-tional Grid +44 (0) 800 111999 by tele-phone once you are outside of the build-ing

Safety 1

0020177746_03 ENERGY Installation and maintenance instructions 5

142 Risk of death from escaping fluegas

If you operate the product with an empty con-densate trap siphon then flue gas may es-cape into the room air

In order to operate the product ensure thatthe condensate trap siphon is always full

143 Risk of death due to blocked orleaking flue gas routes

Installation errors damage tampering unau-thorised installation sites or similar can causeflue gas to escape and result in a risk of pois-oning

What to do if you smell flue gas in the prop-erty

Open all accessible doors and windowsfully to provide ventilation

Switch off the product Check the flue gas routes in the product

and the flue gas diversions

144 Risk of death due to explosive andflammable materials

Do not use the product in storage roomsthat contain explosive or flammable sub-stances (such as petrol paper or paint)

145 Risk of death from electric shock

There is a risk of death from electric shock ifyou touch live components

Before commencing work on the product

Unplug the mains plug Or disconnect the product from the power

supply by switching off all power supplies(electrical partition with a contact gap of atleast 3 mm eg fuse or circuit breaker)

Secure against being switched back onagain

Wait for at least 3 minutes until the capa-citors have discharged

Check that there is no voltage

146 Risk of death due to lack of safetydevices

The schematic drawings included in this doc-ument do not show all safety devices re-quired for correct installation

Install the necessary safety devices in thesystem

Observe the applicable national and inter-national laws standards and guidelines

147 Risk of poisoning and burns causedby escaping hot flue gases

Only operate the product if the airflue pipehas been completely installed

With the exception of short periods fortesting purposes only operate the productwhen the front casing is installed andclosed

148 Risk of being burned or scalded byhot components

Only carry out work on these componentsonce they have cooled down

149 Risk of injury due to the heavyweight of the product

Make sure that the product is transportedby at least two people

1410 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the fluesystem

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similarlocations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1411 Risk of material damage caused byfrost

Do not install the product in rooms proneto frost

1 Safety

6 Installation and maintenance instructions ENERGY 0020177746_03

1412 Risk of material damage caused byusing an unsuitable tool

Use the correct tool to tighten or loosenthreaded connections

15 Regulations (directives lawsstandards)

Observe the national regulations stand-ards guidelines and laws

Notes on the documentation 2

0020177746_03 ENERGY Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Validity of the instructions

These instructions apply only to

Product article number

Article number Gas CouncilNumber

ENERGY 25c -A (H-GB)

0010015652 47-019-24

ENERGY 30c -A (H-GB)

0010015653 47-019-25

ENERGY 35c -A (H-GB)

0010015654 47-019-26

24 Benchmark

Glow-worm is a licensed member of the BenchmarkScheme

Benchmark places responsibilities on both manufacturersand installers The purpose is to ensure that customers areprovided with the correct equipment for their needs that it isinstalled commissioned and serviced in accordance with themanufacturerrsquos instructions by a competent person approvedat the time by the Health and Safety Executive and that itmeets the requirements of the appropriate Building Regu-lations The Benchmark Checklist can be used to demon-strate compliance with Building Regulations and should beprovided to the customer for future reference

Installers are required to carry out installation commission-ing and servicing work in accordance with the BenchmarkCode of Practice which is available from the Heating andHotwater Industry Council who manage and promote theScheme

Benchmark is managed and promoted by the Heating andHotwater Industry Council

For more information visit wwwcentralheatingcouk

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

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

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

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

For identification purposes 7th to 16thdigits = product article number

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

ENERGY c Product description

2H G20 ndash 20 kPa(20 mbar)

Factory setting for type of gas and gasconnection pressure

Cat Approved gas category

Condensing techno-logy

Efficiency class of the boiler in accord-ance with EC Directive 9242EEC

Type Xx3(x) Permissible flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

4 Set-up

8 Installation and maintenance instructions ENERGY 0020177746_03

Information on theidentification plate

Meaning

Read the instructions

GC no Gas council number

33 Functional elements Combination unit

15

12

11

10

8

9

7

5

6

4

3

2

1

18

17

20 19

14

16

13

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Condensate siphon

5 Flue gas pipe

6 Pressure sensor

7 Flue gas analysis point(for rear flue gas con-nection)

8 Ignition transformer

9 Gas valve

10 Air intake pipe

11 Fan

12 Supply air measuringstub pipe (for upper fluegas connection)

13 Flue gas analysis point(for upper flue gasconnection)

14 Primary heat exchanger

15 Heating expansionvessel

16 Purge hose

17 Volume flow sensor

18 Heating pump

19 Bypass

20 3-way valve

34 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend 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 yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete and intact

Number Designation

1 Heat generator

1 Unit mounting bracket

1 Flexible condensate discharge pipe

6 34 seals

4 12 seals

1 Service valve

1 Gas stopcock

1 Filling device

Set-up 4

0020177746_03 ENERGY Installation and maintenance instructions 9

Number Designation

2 Connection pipe (heating flow and return)

1 Cold water connection pipe

1 Domestic hot water connection pipe

1 Gas pipe

1 Expansion relief valve discharge pipe

1 Mounting template

1 Enclosed documentation

44 Dimensions

96121

34

123185

390

12358 58

170

702

150

280

1 2 3 4 5

7

6

1 Heating flow

2 Hot water connection

3 Gas connection

4 Cold water connection

5 Heating return

6 Connection on the backof the airflue pipe

7 Connection on the topof the airflue pipe

45 Minimum clearances

CC

AB

D

Minimum clearance

A 150 mm (top airflue gas connection)

20 mm (airflue gas connection on the rear)

B 150 mm

C 5 mm

(70 mm if the side panels ought to be removed)

D 600 mm

It is not necessary to maintain a clearance between theproduct and components made of combustible materials thatgo beyond the minimum clearances

46 Using the mounting template

Use the mounting template to ascertain the locations atwhich you need to drill holes

47 Wall-mounting the product

Note

If you are using the rear airflue gas connectioninstall the airflue pipe before you wall-mount theproduct

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the operational weight of the product

2 Check if the supplied fixing material may be used forthe wall

4 Set-up

10 Installation and maintenance instructions ENERGY 0020177746_03

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial 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 suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

Conditions The fixing material may not be used for the wall

Wall-mount the product as described using the permittedfixing material provided on-site

48 Removinginstalling the front casing

481 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

482 Installing the front casing

Refit the components in the reverse order

49 Removinginstalling the side section

491 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least70 mm) you can remove the side section to fa-cilitate maintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

492 Installing the side section

Refit the components in the reverse order

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 11

5 Installation

DangerRisk of scalding andor damage due toincorrect installation leading to escapingwater

Mechanical stresses in the connection pipesmay lead to leaks

Ensure that there is no mechanical stresswhen installing the connection pipes

CautionRisk of material damage caused byresidues in the pipelines

Welding remnants sealing residues dirt orother residues in the pipelines may damagethe product

Flush the heating installation thoroughlybefore installing the product

51 Checking the gas meter

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

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of material damage caused by corro-sion

Due to non-diffusion-tight plastic pipes in theheating installation air gets into the heatingwater Air in the heating water causes corro-sion in the heat generator circuit and in theproduct

If you use non-diffusion-tight plastic pipesin the heating installation ensure that noair gets into the heat generator circuit

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connectors if the connectorsare not yet screwed to the service valves

Note

Apply heat insulation to the water pipes to theboiler outlet and to the installation

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the installation

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return valve at the products outlet(heating flow)

2 Ensure that the installation has the following compon-ents

ndash A cold water stopcock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas pipe before start-up

3 Check whether the connections (rarr Page 20) are leak-tight

5 Installation

12 Installation and maintenance instructions ENERGY 0020177746_03

53 Connecting the drain pipework for theexpansion relief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The piping must be installed in such a way that youcan see when water drips out

54 Connecting the condensate discharge pipe

1

2

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

Use PVC or any other material that is suitable for drain-ing the non-neutralised condensate

If you cannot guarantee that the materials from which thedrain pipework is made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate traps (1) Use the supplied drainhose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burrs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

For any installation the condensate must be free flowingand not be possible for air back-pressure to prevent wa-ter flow

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat input below 70 kW

541 Condensate drainage systems

5411 Internal soil and vent pipe

Oslash19mm min

5412 External soil and vent pipe

L = 3m max

Oslash19mm min

Oslash30mm

5413 External termination into a gulley or hopper

L = 3m max

Oslash19mm min

Oslash30mm

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 13

5414 Internal termination into combined sinkwaste

Oslash30mm

Oslash19mm min

5415 Internal termination downstream of sinkwaste

Oslash30mm

Oslash19mm min

5416 External termination into soakaway

400m

m m

in

300m

m m

in25

mm

min

500mm min

Oslash100mm

L = 3m max

Oslash19mm min

Oslash30mm

5417 External termination into rain water downpipe

Oslash19mm min

Oslash30mm

55 Electrical installation

DangerRisk of death from electric shock

The power supply terminals L and N remainlive even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

Only qualified electricians may carry out the electrical install-ation

551 Opening the electronics box

B

B

A

Follow the instructions in the specified sequence

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 3: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Contents

0020177746_03 ENERGY Installation and maintenance instructions 3

J Pipe lengths for the airflue pipe 46

J1 Length of the C13 type airflue pipe 46

J2 Length of the C33 type airflue pipe 46

J3 Length of the C43 type airflue pipe 46

K Technical data 46

Index 49

1 Safety

4 Installation and maintenance instructions ENERGY 0020177746_03

1 Safety

11 Action-related warnings

Classification of action-related warningsThe action-related warnings are classified inaccordance with the severity of the possibledanger using the following warning signs andsignal words

Warning symbols and signal wordsDangerImminent danger to life or risk ofsevere personal injury

DangerRisk of death from electric shock

WarningRisk of minor personal injury

CautionRisk of material or environmentaldamage

12 Risk caused by inadequatequalifications

ndash Set-upndash Dismantlingndash Installationndash Start-upndash Inspection and maintenancendash Repairndash Decommissioning

Observe all instructions that are includedwith the product

Proceed in accordance with current tech-nology

Observe all applicable directives stand-ards laws and other regulations

13 Intended use

There is a risk of injury or death to the user orothers or of damage to the product and otherproperty in the event of improper use or usefor which it is not intended

The product is intended as a heat generatorfor closed heating installations and for hotwater generation

Depending on the unit type the productsreferred to in these instructions must only beinstalled and operated in conjunction with the

airflue pipe accessories listed in the otherapplicable documents

Intended use includes the following

ndash observance of accompanying operatinginstallation and servicing instructions forthe product and any other system compon-ents

ndash installing and fitting the product in accord-ance with the product and system approval

ndash compliance with all inspection and main-tenance conditions listed in the instruc-tions

Intended use also covers installation in ac-cordance with the IP code

Any other use that is not specified in these in-structions or use beyond that specified in thisdocument shall be considered improper useAny direct use in industrial or commercialprocesses is also deemed to be improper

Caution

Improper use of any kind is prohibited

14 General safety information

141 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 (eg lighters

matches) Do not smoke Do not use any electrical switches mains

plugs doorbells telephones or other com-munication systems in the building

If it is safe to do so close the emergencycontrol valve or the main isolator

If possible close the gas isolator cock onthe product

Warn other occupants in the building byyelling or banging on doors or walls

Leave the building immediately and ensurethat others do not enter the building

Notify the gas supply company or the Na-tional Grid +44 (0) 800 111999 by tele-phone once you are outside of the build-ing

Safety 1

0020177746_03 ENERGY Installation and maintenance instructions 5

142 Risk of death from escaping fluegas

If you operate the product with an empty con-densate trap siphon then flue gas may es-cape into the room air

In order to operate the product ensure thatthe condensate trap siphon is always full

143 Risk of death due to blocked orleaking flue gas routes

Installation errors damage tampering unau-thorised installation sites or similar can causeflue gas to escape and result in a risk of pois-oning

What to do if you smell flue gas in the prop-erty

Open all accessible doors and windowsfully to provide ventilation

Switch off the product Check the flue gas routes in the product

and the flue gas diversions

144 Risk of death due to explosive andflammable materials

Do not use the product in storage roomsthat contain explosive or flammable sub-stances (such as petrol paper or paint)

145 Risk of death from electric shock

There is a risk of death from electric shock ifyou touch live components

Before commencing work on the product

Unplug the mains plug Or disconnect the product from the power

supply by switching off all power supplies(electrical partition with a contact gap of atleast 3 mm eg fuse or circuit breaker)

Secure against being switched back onagain

Wait for at least 3 minutes until the capa-citors have discharged

Check that there is no voltage

146 Risk of death due to lack of safetydevices

The schematic drawings included in this doc-ument do not show all safety devices re-quired for correct installation

Install the necessary safety devices in thesystem

Observe the applicable national and inter-national laws standards and guidelines

147 Risk of poisoning and burns causedby escaping hot flue gases

Only operate the product if the airflue pipehas been completely installed

With the exception of short periods fortesting purposes only operate the productwhen the front casing is installed andclosed

148 Risk of being burned or scalded byhot components

Only carry out work on these componentsonce they have cooled down

149 Risk of injury due to the heavyweight of the product

Make sure that the product is transportedby at least two people

1410 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the fluesystem

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similarlocations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1411 Risk of material damage caused byfrost

Do not install the product in rooms proneto frost

1 Safety

6 Installation and maintenance instructions ENERGY 0020177746_03

1412 Risk of material damage caused byusing an unsuitable tool

Use the correct tool to tighten or loosenthreaded connections

15 Regulations (directives lawsstandards)

Observe the national regulations stand-ards guidelines and laws

Notes on the documentation 2

0020177746_03 ENERGY Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Validity of the instructions

These instructions apply only to

Product article number

Article number Gas CouncilNumber

ENERGY 25c -A (H-GB)

0010015652 47-019-24

ENERGY 30c -A (H-GB)

0010015653 47-019-25

ENERGY 35c -A (H-GB)

0010015654 47-019-26

24 Benchmark

Glow-worm is a licensed member of the BenchmarkScheme

Benchmark places responsibilities on both manufacturersand installers The purpose is to ensure that customers areprovided with the correct equipment for their needs that it isinstalled commissioned and serviced in accordance with themanufacturerrsquos instructions by a competent person approvedat the time by the Health and Safety Executive and that itmeets the requirements of the appropriate Building Regu-lations The Benchmark Checklist can be used to demon-strate compliance with Building Regulations and should beprovided to the customer for future reference

Installers are required to carry out installation commission-ing and servicing work in accordance with the BenchmarkCode of Practice which is available from the Heating andHotwater Industry Council who manage and promote theScheme

Benchmark is managed and promoted by the Heating andHotwater Industry Council

For more information visit wwwcentralheatingcouk

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

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

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

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

For identification purposes 7th to 16thdigits = product article number

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

ENERGY c Product description

2H G20 ndash 20 kPa(20 mbar)

Factory setting for type of gas and gasconnection pressure

Cat Approved gas category

Condensing techno-logy

Efficiency class of the boiler in accord-ance with EC Directive 9242EEC

Type Xx3(x) Permissible flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

4 Set-up

8 Installation and maintenance instructions ENERGY 0020177746_03

Information on theidentification plate

Meaning

Read the instructions

GC no Gas council number

33 Functional elements Combination unit

15

12

11

10

8

9

7

5

6

4

3

2

1

18

17

20 19

14

16

13

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Condensate siphon

5 Flue gas pipe

6 Pressure sensor

7 Flue gas analysis point(for rear flue gas con-nection)

8 Ignition transformer

9 Gas valve

10 Air intake pipe

11 Fan

12 Supply air measuringstub pipe (for upper fluegas connection)

13 Flue gas analysis point(for upper flue gasconnection)

14 Primary heat exchanger

15 Heating expansionvessel

16 Purge hose

17 Volume flow sensor

18 Heating pump

19 Bypass

20 3-way valve

34 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend 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 yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete and intact

Number Designation

1 Heat generator

1 Unit mounting bracket

1 Flexible condensate discharge pipe

6 34 seals

4 12 seals

1 Service valve

1 Gas stopcock

1 Filling device

Set-up 4

0020177746_03 ENERGY Installation and maintenance instructions 9

Number Designation

2 Connection pipe (heating flow and return)

1 Cold water connection pipe

1 Domestic hot water connection pipe

1 Gas pipe

1 Expansion relief valve discharge pipe

1 Mounting template

1 Enclosed documentation

44 Dimensions

96121

34

123185

390

12358 58

170

702

150

280

1 2 3 4 5

7

6

1 Heating flow

2 Hot water connection

3 Gas connection

4 Cold water connection

5 Heating return

6 Connection on the backof the airflue pipe

7 Connection on the topof the airflue pipe

45 Minimum clearances

CC

AB

D

Minimum clearance

A 150 mm (top airflue gas connection)

20 mm (airflue gas connection on the rear)

B 150 mm

C 5 mm

(70 mm if the side panels ought to be removed)

D 600 mm

It is not necessary to maintain a clearance between theproduct and components made of combustible materials thatgo beyond the minimum clearances

46 Using the mounting template

Use the mounting template to ascertain the locations atwhich you need to drill holes

47 Wall-mounting the product

Note

If you are using the rear airflue gas connectioninstall the airflue pipe before you wall-mount theproduct

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the operational weight of the product

2 Check if the supplied fixing material may be used forthe wall

4 Set-up

10 Installation and maintenance instructions ENERGY 0020177746_03

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial 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 suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

Conditions The fixing material may not be used for the wall

Wall-mount the product as described using the permittedfixing material provided on-site

48 Removinginstalling the front casing

481 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

482 Installing the front casing

Refit the components in the reverse order

49 Removinginstalling the side section

491 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least70 mm) you can remove the side section to fa-cilitate maintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

492 Installing the side section

Refit the components in the reverse order

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 11

5 Installation

DangerRisk of scalding andor damage due toincorrect installation leading to escapingwater

Mechanical stresses in the connection pipesmay lead to leaks

Ensure that there is no mechanical stresswhen installing the connection pipes

CautionRisk of material damage caused byresidues in the pipelines

Welding remnants sealing residues dirt orother residues in the pipelines may damagethe product

Flush the heating installation thoroughlybefore installing the product

51 Checking the gas meter

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

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of material damage caused by corro-sion

Due to non-diffusion-tight plastic pipes in theheating installation air gets into the heatingwater Air in the heating water causes corro-sion in the heat generator circuit and in theproduct

If you use non-diffusion-tight plastic pipesin the heating installation ensure that noair gets into the heat generator circuit

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connectors if the connectorsare not yet screwed to the service valves

Note

Apply heat insulation to the water pipes to theboiler outlet and to the installation

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the installation

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return valve at the products outlet(heating flow)

2 Ensure that the installation has the following compon-ents

ndash A cold water stopcock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas pipe before start-up

3 Check whether the connections (rarr Page 20) are leak-tight

5 Installation

12 Installation and maintenance instructions ENERGY 0020177746_03

53 Connecting the drain pipework for theexpansion relief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The piping must be installed in such a way that youcan see when water drips out

54 Connecting the condensate discharge pipe

1

2

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

Use PVC or any other material that is suitable for drain-ing the non-neutralised condensate

If you cannot guarantee that the materials from which thedrain pipework is made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate traps (1) Use the supplied drainhose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burrs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

For any installation the condensate must be free flowingand not be possible for air back-pressure to prevent wa-ter flow

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat input below 70 kW

541 Condensate drainage systems

5411 Internal soil and vent pipe

Oslash19mm min

5412 External soil and vent pipe

L = 3m max

Oslash19mm min

Oslash30mm

5413 External termination into a gulley or hopper

L = 3m max

Oslash19mm min

Oslash30mm

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 13

5414 Internal termination into combined sinkwaste

Oslash30mm

Oslash19mm min

5415 Internal termination downstream of sinkwaste

Oslash30mm

Oslash19mm min

5416 External termination into soakaway

400m

m m

in

300m

m m

in25

mm

min

500mm min

Oslash100mm

L = 3m max

Oslash19mm min

Oslash30mm

5417 External termination into rain water downpipe

Oslash19mm min

Oslash30mm

55 Electrical installation

DangerRisk of death from electric shock

The power supply terminals L and N remainlive even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

Only qualified electricians may carry out the electrical install-ation

551 Opening the electronics box

B

B

A

Follow the instructions in the specified sequence

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 4: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

1 Safety

4 Installation and maintenance instructions ENERGY 0020177746_03

1 Safety

11 Action-related warnings

Classification of action-related warningsThe action-related warnings are classified inaccordance with the severity of the possibledanger using the following warning signs andsignal words

Warning symbols and signal wordsDangerImminent danger to life or risk ofsevere personal injury

DangerRisk of death from electric shock

WarningRisk of minor personal injury

CautionRisk of material or environmentaldamage

12 Risk caused by inadequatequalifications

ndash Set-upndash Dismantlingndash Installationndash Start-upndash Inspection and maintenancendash Repairndash Decommissioning

Observe all instructions that are includedwith the product

Proceed in accordance with current tech-nology

Observe all applicable directives stand-ards laws and other regulations

13 Intended use

There is a risk of injury or death to the user orothers or of damage to the product and otherproperty in the event of improper use or usefor which it is not intended

The product is intended as a heat generatorfor closed heating installations and for hotwater generation

Depending on the unit type the productsreferred to in these instructions must only beinstalled and operated in conjunction with the

airflue pipe accessories listed in the otherapplicable documents

Intended use includes the following

ndash observance of accompanying operatinginstallation and servicing instructions forthe product and any other system compon-ents

ndash installing and fitting the product in accord-ance with the product and system approval

ndash compliance with all inspection and main-tenance conditions listed in the instruc-tions

Intended use also covers installation in ac-cordance with the IP code

Any other use that is not specified in these in-structions or use beyond that specified in thisdocument shall be considered improper useAny direct use in industrial or commercialprocesses is also deemed to be improper

Caution

Improper use of any kind is prohibited

14 General safety information

141 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 (eg lighters

matches) Do not smoke Do not use any electrical switches mains

plugs doorbells telephones or other com-munication systems in the building

If it is safe to do so close the emergencycontrol valve or the main isolator

If possible close the gas isolator cock onthe product

Warn other occupants in the building byyelling or banging on doors or walls

Leave the building immediately and ensurethat others do not enter the building

Notify the gas supply company or the Na-tional Grid +44 (0) 800 111999 by tele-phone once you are outside of the build-ing

Safety 1

0020177746_03 ENERGY Installation and maintenance instructions 5

142 Risk of death from escaping fluegas

If you operate the product with an empty con-densate trap siphon then flue gas may es-cape into the room air

In order to operate the product ensure thatthe condensate trap siphon is always full

143 Risk of death due to blocked orleaking flue gas routes

Installation errors damage tampering unau-thorised installation sites or similar can causeflue gas to escape and result in a risk of pois-oning

What to do if you smell flue gas in the prop-erty

Open all accessible doors and windowsfully to provide ventilation

Switch off the product Check the flue gas routes in the product

and the flue gas diversions

144 Risk of death due to explosive andflammable materials

Do not use the product in storage roomsthat contain explosive or flammable sub-stances (such as petrol paper or paint)

145 Risk of death from electric shock

There is a risk of death from electric shock ifyou touch live components

Before commencing work on the product

Unplug the mains plug Or disconnect the product from the power

supply by switching off all power supplies(electrical partition with a contact gap of atleast 3 mm eg fuse or circuit breaker)

Secure against being switched back onagain

Wait for at least 3 minutes until the capa-citors have discharged

Check that there is no voltage

146 Risk of death due to lack of safetydevices

The schematic drawings included in this doc-ument do not show all safety devices re-quired for correct installation

Install the necessary safety devices in thesystem

Observe the applicable national and inter-national laws standards and guidelines

147 Risk of poisoning and burns causedby escaping hot flue gases

Only operate the product if the airflue pipehas been completely installed

With the exception of short periods fortesting purposes only operate the productwhen the front casing is installed andclosed

148 Risk of being burned or scalded byhot components

Only carry out work on these componentsonce they have cooled down

149 Risk of injury due to the heavyweight of the product

Make sure that the product is transportedby at least two people

1410 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the fluesystem

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similarlocations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1411 Risk of material damage caused byfrost

Do not install the product in rooms proneto frost

1 Safety

6 Installation and maintenance instructions ENERGY 0020177746_03

1412 Risk of material damage caused byusing an unsuitable tool

Use the correct tool to tighten or loosenthreaded connections

15 Regulations (directives lawsstandards)

Observe the national regulations stand-ards guidelines and laws

Notes on the documentation 2

0020177746_03 ENERGY Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Validity of the instructions

These instructions apply only to

Product article number

Article number Gas CouncilNumber

ENERGY 25c -A (H-GB)

0010015652 47-019-24

ENERGY 30c -A (H-GB)

0010015653 47-019-25

ENERGY 35c -A (H-GB)

0010015654 47-019-26

24 Benchmark

Glow-worm is a licensed member of the BenchmarkScheme

Benchmark places responsibilities on both manufacturersand installers The purpose is to ensure that customers areprovided with the correct equipment for their needs that it isinstalled commissioned and serviced in accordance with themanufacturerrsquos instructions by a competent person approvedat the time by the Health and Safety Executive and that itmeets the requirements of the appropriate Building Regu-lations The Benchmark Checklist can be used to demon-strate compliance with Building Regulations and should beprovided to the customer for future reference

Installers are required to carry out installation commission-ing and servicing work in accordance with the BenchmarkCode of Practice which is available from the Heating andHotwater Industry Council who manage and promote theScheme

Benchmark is managed and promoted by the Heating andHotwater Industry Council

For more information visit wwwcentralheatingcouk

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

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

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

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

For identification purposes 7th to 16thdigits = product article number

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

ENERGY c Product description

2H G20 ndash 20 kPa(20 mbar)

Factory setting for type of gas and gasconnection pressure

Cat Approved gas category

Condensing techno-logy

Efficiency class of the boiler in accord-ance with EC Directive 9242EEC

Type Xx3(x) Permissible flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

4 Set-up

8 Installation and maintenance instructions ENERGY 0020177746_03

Information on theidentification plate

Meaning

Read the instructions

GC no Gas council number

33 Functional elements Combination unit

15

12

11

10

8

9

7

5

6

4

3

2

1

18

17

20 19

14

16

13

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Condensate siphon

5 Flue gas pipe

6 Pressure sensor

7 Flue gas analysis point(for rear flue gas con-nection)

8 Ignition transformer

9 Gas valve

10 Air intake pipe

11 Fan

12 Supply air measuringstub pipe (for upper fluegas connection)

13 Flue gas analysis point(for upper flue gasconnection)

14 Primary heat exchanger

15 Heating expansionvessel

16 Purge hose

17 Volume flow sensor

18 Heating pump

19 Bypass

20 3-way valve

34 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend 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 yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete and intact

Number Designation

1 Heat generator

1 Unit mounting bracket

1 Flexible condensate discharge pipe

6 34 seals

4 12 seals

1 Service valve

1 Gas stopcock

1 Filling device

Set-up 4

0020177746_03 ENERGY Installation and maintenance instructions 9

Number Designation

2 Connection pipe (heating flow and return)

1 Cold water connection pipe

1 Domestic hot water connection pipe

1 Gas pipe

1 Expansion relief valve discharge pipe

1 Mounting template

1 Enclosed documentation

44 Dimensions

96121

34

123185

390

12358 58

170

702

150

280

1 2 3 4 5

7

6

1 Heating flow

2 Hot water connection

3 Gas connection

4 Cold water connection

5 Heating return

6 Connection on the backof the airflue pipe

7 Connection on the topof the airflue pipe

45 Minimum clearances

CC

AB

D

Minimum clearance

A 150 mm (top airflue gas connection)

20 mm (airflue gas connection on the rear)

B 150 mm

C 5 mm

(70 mm if the side panels ought to be removed)

D 600 mm

It is not necessary to maintain a clearance between theproduct and components made of combustible materials thatgo beyond the minimum clearances

46 Using the mounting template

Use the mounting template to ascertain the locations atwhich you need to drill holes

47 Wall-mounting the product

Note

If you are using the rear airflue gas connectioninstall the airflue pipe before you wall-mount theproduct

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the operational weight of the product

2 Check if the supplied fixing material may be used forthe wall

4 Set-up

10 Installation and maintenance instructions ENERGY 0020177746_03

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial 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 suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

Conditions The fixing material may not be used for the wall

Wall-mount the product as described using the permittedfixing material provided on-site

48 Removinginstalling the front casing

481 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

482 Installing the front casing

Refit the components in the reverse order

49 Removinginstalling the side section

491 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least70 mm) you can remove the side section to fa-cilitate maintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

492 Installing the side section

Refit the components in the reverse order

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 11

5 Installation

DangerRisk of scalding andor damage due toincorrect installation leading to escapingwater

Mechanical stresses in the connection pipesmay lead to leaks

Ensure that there is no mechanical stresswhen installing the connection pipes

CautionRisk of material damage caused byresidues in the pipelines

Welding remnants sealing residues dirt orother residues in the pipelines may damagethe product

Flush the heating installation thoroughlybefore installing the product

51 Checking the gas meter

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

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of material damage caused by corro-sion

Due to non-diffusion-tight plastic pipes in theheating installation air gets into the heatingwater Air in the heating water causes corro-sion in the heat generator circuit and in theproduct

If you use non-diffusion-tight plastic pipesin the heating installation ensure that noair gets into the heat generator circuit

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connectors if the connectorsare not yet screwed to the service valves

Note

Apply heat insulation to the water pipes to theboiler outlet and to the installation

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the installation

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return valve at the products outlet(heating flow)

2 Ensure that the installation has the following compon-ents

ndash A cold water stopcock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas pipe before start-up

3 Check whether the connections (rarr Page 20) are leak-tight

5 Installation

12 Installation and maintenance instructions ENERGY 0020177746_03

53 Connecting the drain pipework for theexpansion relief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The piping must be installed in such a way that youcan see when water drips out

54 Connecting the condensate discharge pipe

1

2

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

Use PVC or any other material that is suitable for drain-ing the non-neutralised condensate

If you cannot guarantee that the materials from which thedrain pipework is made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate traps (1) Use the supplied drainhose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burrs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

For any installation the condensate must be free flowingand not be possible for air back-pressure to prevent wa-ter flow

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat input below 70 kW

541 Condensate drainage systems

5411 Internal soil and vent pipe

Oslash19mm min

5412 External soil and vent pipe

L = 3m max

Oslash19mm min

Oslash30mm

5413 External termination into a gulley or hopper

L = 3m max

Oslash19mm min

Oslash30mm

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 13

5414 Internal termination into combined sinkwaste

Oslash30mm

Oslash19mm min

5415 Internal termination downstream of sinkwaste

Oslash30mm

Oslash19mm min

5416 External termination into soakaway

400m

m m

in

300m

m m

in25

mm

min

500mm min

Oslash100mm

L = 3m max

Oslash19mm min

Oslash30mm

5417 External termination into rain water downpipe

Oslash19mm min

Oslash30mm

55 Electrical installation

DangerRisk of death from electric shock

The power supply terminals L and N remainlive even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

Only qualified electricians may carry out the electrical install-ation

551 Opening the electronics box

B

B

A

Follow the instructions in the specified sequence

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 5: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Safety 1

0020177746_03 ENERGY Installation and maintenance instructions 5

142 Risk of death from escaping fluegas

If you operate the product with an empty con-densate trap siphon then flue gas may es-cape into the room air

In order to operate the product ensure thatthe condensate trap siphon is always full

143 Risk of death due to blocked orleaking flue gas routes

Installation errors damage tampering unau-thorised installation sites or similar can causeflue gas to escape and result in a risk of pois-oning

What to do if you smell flue gas in the prop-erty

Open all accessible doors and windowsfully to provide ventilation

Switch off the product Check the flue gas routes in the product

and the flue gas diversions

144 Risk of death due to explosive andflammable materials

Do not use the product in storage roomsthat contain explosive or flammable sub-stances (such as petrol paper or paint)

145 Risk of death from electric shock

There is a risk of death from electric shock ifyou touch live components

Before commencing work on the product

Unplug the mains plug Or disconnect the product from the power

supply by switching off all power supplies(electrical partition with a contact gap of atleast 3 mm eg fuse or circuit breaker)

Secure against being switched back onagain

Wait for at least 3 minutes until the capa-citors have discharged

Check that there is no voltage

146 Risk of death due to lack of safetydevices

The schematic drawings included in this doc-ument do not show all safety devices re-quired for correct installation

Install the necessary safety devices in thesystem

Observe the applicable national and inter-national laws standards and guidelines

147 Risk of poisoning and burns causedby escaping hot flue gases

Only operate the product if the airflue pipehas been completely installed

With the exception of short periods fortesting purposes only operate the productwhen the front casing is installed andclosed

148 Risk of being burned or scalded byhot components

Only carry out work on these componentsonce they have cooled down

149 Risk of injury due to the heavyweight of the product

Make sure that the product is transportedby at least two people

1410 Risk of corrosion damage due tounsuitable combustion and roomair

Sprays solvents chlorinated cleaningagents paint adhesives ammonia com-pounds dust or similar substances may leadto corrosion on the product and in the fluesystem

Ensure that the supply of combustion air isalways free of fluorine chlorine sulphurdust etc

Ensure that no chemical substances arestored at the installation site

If you are installing the product inhairdressing salons painters or joinersworkshops cleaning businesses or similarlocations choose a separate installationroom in which the room air is technicallyfree of chemical substances

1411 Risk of material damage caused byfrost

Do not install the product in rooms proneto frost

1 Safety

6 Installation and maintenance instructions ENERGY 0020177746_03

1412 Risk of material damage caused byusing an unsuitable tool

Use the correct tool to tighten or loosenthreaded connections

15 Regulations (directives lawsstandards)

Observe the national regulations stand-ards guidelines and laws

Notes on the documentation 2

0020177746_03 ENERGY Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Validity of the instructions

These instructions apply only to

Product article number

Article number Gas CouncilNumber

ENERGY 25c -A (H-GB)

0010015652 47-019-24

ENERGY 30c -A (H-GB)

0010015653 47-019-25

ENERGY 35c -A (H-GB)

0010015654 47-019-26

24 Benchmark

Glow-worm is a licensed member of the BenchmarkScheme

Benchmark places responsibilities on both manufacturersand installers The purpose is to ensure that customers areprovided with the correct equipment for their needs that it isinstalled commissioned and serviced in accordance with themanufacturerrsquos instructions by a competent person approvedat the time by the Health and Safety Executive and that itmeets the requirements of the appropriate Building Regu-lations The Benchmark Checklist can be used to demon-strate compliance with Building Regulations and should beprovided to the customer for future reference

Installers are required to carry out installation commission-ing and servicing work in accordance with the BenchmarkCode of Practice which is available from the Heating andHotwater Industry Council who manage and promote theScheme

Benchmark is managed and promoted by the Heating andHotwater Industry Council

For more information visit wwwcentralheatingcouk

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

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

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

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

For identification purposes 7th to 16thdigits = product article number

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

ENERGY c Product description

2H G20 ndash 20 kPa(20 mbar)

Factory setting for type of gas and gasconnection pressure

Cat Approved gas category

Condensing techno-logy

Efficiency class of the boiler in accord-ance with EC Directive 9242EEC

Type Xx3(x) Permissible flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

4 Set-up

8 Installation and maintenance instructions ENERGY 0020177746_03

Information on theidentification plate

Meaning

Read the instructions

GC no Gas council number

33 Functional elements Combination unit

15

12

11

10

8

9

7

5

6

4

3

2

1

18

17

20 19

14

16

13

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Condensate siphon

5 Flue gas pipe

6 Pressure sensor

7 Flue gas analysis point(for rear flue gas con-nection)

8 Ignition transformer

9 Gas valve

10 Air intake pipe

11 Fan

12 Supply air measuringstub pipe (for upper fluegas connection)

13 Flue gas analysis point(for upper flue gasconnection)

14 Primary heat exchanger

15 Heating expansionvessel

16 Purge hose

17 Volume flow sensor

18 Heating pump

19 Bypass

20 3-way valve

34 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend 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 yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete and intact

Number Designation

1 Heat generator

1 Unit mounting bracket

1 Flexible condensate discharge pipe

6 34 seals

4 12 seals

1 Service valve

1 Gas stopcock

1 Filling device

Set-up 4

0020177746_03 ENERGY Installation and maintenance instructions 9

Number Designation

2 Connection pipe (heating flow and return)

1 Cold water connection pipe

1 Domestic hot water connection pipe

1 Gas pipe

1 Expansion relief valve discharge pipe

1 Mounting template

1 Enclosed documentation

44 Dimensions

96121

34

123185

390

12358 58

170

702

150

280

1 2 3 4 5

7

6

1 Heating flow

2 Hot water connection

3 Gas connection

4 Cold water connection

5 Heating return

6 Connection on the backof the airflue pipe

7 Connection on the topof the airflue pipe

45 Minimum clearances

CC

AB

D

Minimum clearance

A 150 mm (top airflue gas connection)

20 mm (airflue gas connection on the rear)

B 150 mm

C 5 mm

(70 mm if the side panels ought to be removed)

D 600 mm

It is not necessary to maintain a clearance between theproduct and components made of combustible materials thatgo beyond the minimum clearances

46 Using the mounting template

Use the mounting template to ascertain the locations atwhich you need to drill holes

47 Wall-mounting the product

Note

If you are using the rear airflue gas connectioninstall the airflue pipe before you wall-mount theproduct

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the operational weight of the product

2 Check if the supplied fixing material may be used forthe wall

4 Set-up

10 Installation and maintenance instructions ENERGY 0020177746_03

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial 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 suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

Conditions The fixing material may not be used for the wall

Wall-mount the product as described using the permittedfixing material provided on-site

48 Removinginstalling the front casing

481 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

482 Installing the front casing

Refit the components in the reverse order

49 Removinginstalling the side section

491 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least70 mm) you can remove the side section to fa-cilitate maintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

492 Installing the side section

Refit the components in the reverse order

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 11

5 Installation

DangerRisk of scalding andor damage due toincorrect installation leading to escapingwater

Mechanical stresses in the connection pipesmay lead to leaks

Ensure that there is no mechanical stresswhen installing the connection pipes

CautionRisk of material damage caused byresidues in the pipelines

Welding remnants sealing residues dirt orother residues in the pipelines may damagethe product

Flush the heating installation thoroughlybefore installing the product

51 Checking the gas meter

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

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of material damage caused by corro-sion

Due to non-diffusion-tight plastic pipes in theheating installation air gets into the heatingwater Air in the heating water causes corro-sion in the heat generator circuit and in theproduct

If you use non-diffusion-tight plastic pipesin the heating installation ensure that noair gets into the heat generator circuit

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connectors if the connectorsare not yet screwed to the service valves

Note

Apply heat insulation to the water pipes to theboiler outlet and to the installation

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the installation

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return valve at the products outlet(heating flow)

2 Ensure that the installation has the following compon-ents

ndash A cold water stopcock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas pipe before start-up

3 Check whether the connections (rarr Page 20) are leak-tight

5 Installation

12 Installation and maintenance instructions ENERGY 0020177746_03

53 Connecting the drain pipework for theexpansion relief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The piping must be installed in such a way that youcan see when water drips out

54 Connecting the condensate discharge pipe

1

2

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

Use PVC or any other material that is suitable for drain-ing the non-neutralised condensate

If you cannot guarantee that the materials from which thedrain pipework is made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate traps (1) Use the supplied drainhose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burrs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

For any installation the condensate must be free flowingand not be possible for air back-pressure to prevent wa-ter flow

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat input below 70 kW

541 Condensate drainage systems

5411 Internal soil and vent pipe

Oslash19mm min

5412 External soil and vent pipe

L = 3m max

Oslash19mm min

Oslash30mm

5413 External termination into a gulley or hopper

L = 3m max

Oslash19mm min

Oslash30mm

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 13

5414 Internal termination into combined sinkwaste

Oslash30mm

Oslash19mm min

5415 Internal termination downstream of sinkwaste

Oslash30mm

Oslash19mm min

5416 External termination into soakaway

400m

m m

in

300m

m m

in25

mm

min

500mm min

Oslash100mm

L = 3m max

Oslash19mm min

Oslash30mm

5417 External termination into rain water downpipe

Oslash19mm min

Oslash30mm

55 Electrical installation

DangerRisk of death from electric shock

The power supply terminals L and N remainlive even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

Only qualified electricians may carry out the electrical install-ation

551 Opening the electronics box

B

B

A

Follow the instructions in the specified sequence

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 6: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

1 Safety

6 Installation and maintenance instructions ENERGY 0020177746_03

1412 Risk of material damage caused byusing an unsuitable tool

Use the correct tool to tighten or loosenthreaded connections

15 Regulations (directives lawsstandards)

Observe the national regulations stand-ards guidelines and laws

Notes on the documentation 2

0020177746_03 ENERGY Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Validity of the instructions

These instructions apply only to

Product article number

Article number Gas CouncilNumber

ENERGY 25c -A (H-GB)

0010015652 47-019-24

ENERGY 30c -A (H-GB)

0010015653 47-019-25

ENERGY 35c -A (H-GB)

0010015654 47-019-26

24 Benchmark

Glow-worm is a licensed member of the BenchmarkScheme

Benchmark places responsibilities on both manufacturersand installers The purpose is to ensure that customers areprovided with the correct equipment for their needs that it isinstalled commissioned and serviced in accordance with themanufacturerrsquos instructions by a competent person approvedat the time by the Health and Safety Executive and that itmeets the requirements of the appropriate Building Regu-lations The Benchmark Checklist can be used to demon-strate compliance with Building Regulations and should beprovided to the customer for future reference

Installers are required to carry out installation commission-ing and servicing work in accordance with the BenchmarkCode of Practice which is available from the Heating andHotwater Industry Council who manage and promote theScheme

Benchmark is managed and promoted by the Heating andHotwater Industry Council

For more information visit wwwcentralheatingcouk

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

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

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

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

For identification purposes 7th to 16thdigits = product article number

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

ENERGY c Product description

2H G20 ndash 20 kPa(20 mbar)

Factory setting for type of gas and gasconnection pressure

Cat Approved gas category

Condensing techno-logy

Efficiency class of the boiler in accord-ance with EC Directive 9242EEC

Type Xx3(x) Permissible flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

4 Set-up

8 Installation and maintenance instructions ENERGY 0020177746_03

Information on theidentification plate

Meaning

Read the instructions

GC no Gas council number

33 Functional elements Combination unit

15

12

11

10

8

9

7

5

6

4

3

2

1

18

17

20 19

14

16

13

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Condensate siphon

5 Flue gas pipe

6 Pressure sensor

7 Flue gas analysis point(for rear flue gas con-nection)

8 Ignition transformer

9 Gas valve

10 Air intake pipe

11 Fan

12 Supply air measuringstub pipe (for upper fluegas connection)

13 Flue gas analysis point(for upper flue gasconnection)

14 Primary heat exchanger

15 Heating expansionvessel

16 Purge hose

17 Volume flow sensor

18 Heating pump

19 Bypass

20 3-way valve

34 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend 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 yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete and intact

Number Designation

1 Heat generator

1 Unit mounting bracket

1 Flexible condensate discharge pipe

6 34 seals

4 12 seals

1 Service valve

1 Gas stopcock

1 Filling device

Set-up 4

0020177746_03 ENERGY Installation and maintenance instructions 9

Number Designation

2 Connection pipe (heating flow and return)

1 Cold water connection pipe

1 Domestic hot water connection pipe

1 Gas pipe

1 Expansion relief valve discharge pipe

1 Mounting template

1 Enclosed documentation

44 Dimensions

96121

34

123185

390

12358 58

170

702

150

280

1 2 3 4 5

7

6

1 Heating flow

2 Hot water connection

3 Gas connection

4 Cold water connection

5 Heating return

6 Connection on the backof the airflue pipe

7 Connection on the topof the airflue pipe

45 Minimum clearances

CC

AB

D

Minimum clearance

A 150 mm (top airflue gas connection)

20 mm (airflue gas connection on the rear)

B 150 mm

C 5 mm

(70 mm if the side panels ought to be removed)

D 600 mm

It is not necessary to maintain a clearance between theproduct and components made of combustible materials thatgo beyond the minimum clearances

46 Using the mounting template

Use the mounting template to ascertain the locations atwhich you need to drill holes

47 Wall-mounting the product

Note

If you are using the rear airflue gas connectioninstall the airflue pipe before you wall-mount theproduct

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the operational weight of the product

2 Check if the supplied fixing material may be used forthe wall

4 Set-up

10 Installation and maintenance instructions ENERGY 0020177746_03

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial 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 suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

Conditions The fixing material may not be used for the wall

Wall-mount the product as described using the permittedfixing material provided on-site

48 Removinginstalling the front casing

481 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

482 Installing the front casing

Refit the components in the reverse order

49 Removinginstalling the side section

491 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least70 mm) you can remove the side section to fa-cilitate maintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

492 Installing the side section

Refit the components in the reverse order

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 11

5 Installation

DangerRisk of scalding andor damage due toincorrect installation leading to escapingwater

Mechanical stresses in the connection pipesmay lead to leaks

Ensure that there is no mechanical stresswhen installing the connection pipes

CautionRisk of material damage caused byresidues in the pipelines

Welding remnants sealing residues dirt orother residues in the pipelines may damagethe product

Flush the heating installation thoroughlybefore installing the product

51 Checking the gas meter

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

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of material damage caused by corro-sion

Due to non-diffusion-tight plastic pipes in theheating installation air gets into the heatingwater Air in the heating water causes corro-sion in the heat generator circuit and in theproduct

If you use non-diffusion-tight plastic pipesin the heating installation ensure that noair gets into the heat generator circuit

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connectors if the connectorsare not yet screwed to the service valves

Note

Apply heat insulation to the water pipes to theboiler outlet and to the installation

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the installation

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return valve at the products outlet(heating flow)

2 Ensure that the installation has the following compon-ents

ndash A cold water stopcock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas pipe before start-up

3 Check whether the connections (rarr Page 20) are leak-tight

5 Installation

12 Installation and maintenance instructions ENERGY 0020177746_03

53 Connecting the drain pipework for theexpansion relief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The piping must be installed in such a way that youcan see when water drips out

54 Connecting the condensate discharge pipe

1

2

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

Use PVC or any other material that is suitable for drain-ing the non-neutralised condensate

If you cannot guarantee that the materials from which thedrain pipework is made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate traps (1) Use the supplied drainhose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burrs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

For any installation the condensate must be free flowingand not be possible for air back-pressure to prevent wa-ter flow

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat input below 70 kW

541 Condensate drainage systems

5411 Internal soil and vent pipe

Oslash19mm min

5412 External soil and vent pipe

L = 3m max

Oslash19mm min

Oslash30mm

5413 External termination into a gulley or hopper

L = 3m max

Oslash19mm min

Oslash30mm

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 13

5414 Internal termination into combined sinkwaste

Oslash30mm

Oslash19mm min

5415 Internal termination downstream of sinkwaste

Oslash30mm

Oslash19mm min

5416 External termination into soakaway

400m

m m

in

300m

m m

in25

mm

min

500mm min

Oslash100mm

L = 3m max

Oslash19mm min

Oslash30mm

5417 External termination into rain water downpipe

Oslash19mm min

Oslash30mm

55 Electrical installation

DangerRisk of death from electric shock

The power supply terminals L and N remainlive even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

Only qualified electricians may carry out the electrical install-ation

551 Opening the electronics box

B

B

A

Follow the instructions in the specified sequence

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 7: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Notes on the documentation 2

0020177746_03 ENERGY Installation and maintenance instructions 7

2 Notes on the documentation

21 Observing other applicable documents

You must observe all the operating and installation in-structions included with the system components

22 Storing documents

Pass these instructions and all other applicable docu-ments on to the system operator

23 Validity of the instructions

These instructions apply only to

Product article number

Article number Gas CouncilNumber

ENERGY 25c -A (H-GB)

0010015652 47-019-24

ENERGY 30c -A (H-GB)

0010015653 47-019-25

ENERGY 35c -A (H-GB)

0010015654 47-019-26

24 Benchmark

Glow-worm is a licensed member of the BenchmarkScheme

Benchmark places responsibilities on both manufacturersand installers The purpose is to ensure that customers areprovided with the correct equipment for their needs that it isinstalled commissioned and serviced in accordance with themanufacturerrsquos instructions by a competent person approvedat the time by the Health and Safety Executive and that itmeets the requirements of the appropriate Building Regu-lations The Benchmark Checklist can be used to demon-strate compliance with Building Regulations and should beprovided to the customer for future reference

Installers are required to carry out installation commission-ing and servicing work in accordance with the BenchmarkCode of Practice which is available from the Heating andHotwater Industry Council who manage and promote theScheme

Benchmark is managed and promoted by the Heating andHotwater Industry Council

For more information visit wwwcentralheatingcouk

3 Product description

31 Compartment Ventilation

The boilers are very high efficiency appliances

As a consequence the heat loss from the appliance casingduring operation is very low

Compartment ventilation is not required as the products areonly certified and can only be fitted with a concentric fluesystem

32 Information on the identification plate

The identification plate is mounted on the underside of theproduct in the factory

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

Information on theidentification plate

Meaning

Barcode with serial number

Serial number For quality control purposes 3rd and 4thdigits = year of production

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

For identification purposes 7th to 16thdigits = product article number

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

ENERGY c Product description

2H G20 ndash 20 kPa(20 mbar)

Factory setting for type of gas and gasconnection pressure

Cat Approved gas category

Condensing techno-logy

Efficiency class of the boiler in accord-ance with EC Directive 9242EEC

Type Xx3(x) Permissible flue gas connections

PMS Maximum water pressure in heatingmode

PMW Maximum water pressure in hot waterhandling mode

VHz Electric connection

W Max electrical power consumption

IP Level of protection

Heating mode

Hot water generation

Pn Nominal heat output range in heatingmode

Pnc Nominal heat output range in heatingmode (condensing technology)

P Nominal heat output range in hot waterhandling mode

Qn Nominal heating load range in heatingmode

Qnw Nominal heating load range in hot waterhandling mode

Tmax Max flow temperature

NOx NOx class for the product

Code (DSN) Specific product code

4 Set-up

8 Installation and maintenance instructions ENERGY 0020177746_03

Information on theidentification plate

Meaning

Read the instructions

GC no Gas council number

33 Functional elements Combination unit

15

12

11

10

8

9

7

5

6

4

3

2

1

18

17

20 19

14

16

13

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Condensate siphon

5 Flue gas pipe

6 Pressure sensor

7 Flue gas analysis point(for rear flue gas con-nection)

8 Ignition transformer

9 Gas valve

10 Air intake pipe

11 Fan

12 Supply air measuringstub pipe (for upper fluegas connection)

13 Flue gas analysis point(for upper flue gasconnection)

14 Primary heat exchanger

15 Heating expansionvessel

16 Purge hose

17 Volume flow sensor

18 Heating pump

19 Bypass

20 3-way valve

34 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend 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 yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete and intact

Number Designation

1 Heat generator

1 Unit mounting bracket

1 Flexible condensate discharge pipe

6 34 seals

4 12 seals

1 Service valve

1 Gas stopcock

1 Filling device

Set-up 4

0020177746_03 ENERGY Installation and maintenance instructions 9

Number Designation

2 Connection pipe (heating flow and return)

1 Cold water connection pipe

1 Domestic hot water connection pipe

1 Gas pipe

1 Expansion relief valve discharge pipe

1 Mounting template

1 Enclosed documentation

44 Dimensions

96121

34

123185

390

12358 58

170

702

150

280

1 2 3 4 5

7

6

1 Heating flow

2 Hot water connection

3 Gas connection

4 Cold water connection

5 Heating return

6 Connection on the backof the airflue pipe

7 Connection on the topof the airflue pipe

45 Minimum clearances

CC

AB

D

Minimum clearance

A 150 mm (top airflue gas connection)

20 mm (airflue gas connection on the rear)

B 150 mm

C 5 mm

(70 mm if the side panels ought to be removed)

D 600 mm

It is not necessary to maintain a clearance between theproduct and components made of combustible materials thatgo beyond the minimum clearances

46 Using the mounting template

Use the mounting template to ascertain the locations atwhich you need to drill holes

47 Wall-mounting the product

Note

If you are using the rear airflue gas connectioninstall the airflue pipe before you wall-mount theproduct

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the operational weight of the product

2 Check if the supplied fixing material may be used forthe wall

4 Set-up

10 Installation and maintenance instructions ENERGY 0020177746_03

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial 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 suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

Conditions The fixing material may not be used for the wall

Wall-mount the product as described using the permittedfixing material provided on-site

48 Removinginstalling the front casing

481 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

482 Installing the front casing

Refit the components in the reverse order

49 Removinginstalling the side section

491 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least70 mm) you can remove the side section to fa-cilitate maintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

492 Installing the side section

Refit the components in the reverse order

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 11

5 Installation

DangerRisk of scalding andor damage due toincorrect installation leading to escapingwater

Mechanical stresses in the connection pipesmay lead to leaks

Ensure that there is no mechanical stresswhen installing the connection pipes

CautionRisk of material damage caused byresidues in the pipelines

Welding remnants sealing residues dirt orother residues in the pipelines may damagethe product

Flush the heating installation thoroughlybefore installing the product

51 Checking the gas meter

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

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of material damage caused by corro-sion

Due to non-diffusion-tight plastic pipes in theheating installation air gets into the heatingwater Air in the heating water causes corro-sion in the heat generator circuit and in theproduct

If you use non-diffusion-tight plastic pipesin the heating installation ensure that noair gets into the heat generator circuit

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connectors if the connectorsare not yet screwed to the service valves

Note

Apply heat insulation to the water pipes to theboiler outlet and to the installation

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the installation

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return valve at the products outlet(heating flow)

2 Ensure that the installation has the following compon-ents

ndash A cold water stopcock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas pipe before start-up

3 Check whether the connections (rarr Page 20) are leak-tight

5 Installation

12 Installation and maintenance instructions ENERGY 0020177746_03

53 Connecting the drain pipework for theexpansion relief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The piping must be installed in such a way that youcan see when water drips out

54 Connecting the condensate discharge pipe

1

2

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

Use PVC or any other material that is suitable for drain-ing the non-neutralised condensate

If you cannot guarantee that the materials from which thedrain pipework is made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate traps (1) Use the supplied drainhose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burrs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

For any installation the condensate must be free flowingand not be possible for air back-pressure to prevent wa-ter flow

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat input below 70 kW

541 Condensate drainage systems

5411 Internal soil and vent pipe

Oslash19mm min

5412 External soil and vent pipe

L = 3m max

Oslash19mm min

Oslash30mm

5413 External termination into a gulley or hopper

L = 3m max

Oslash19mm min

Oslash30mm

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 13

5414 Internal termination into combined sinkwaste

Oslash30mm

Oslash19mm min

5415 Internal termination downstream of sinkwaste

Oslash30mm

Oslash19mm min

5416 External termination into soakaway

400m

m m

in

300m

m m

in25

mm

min

500mm min

Oslash100mm

L = 3m max

Oslash19mm min

Oslash30mm

5417 External termination into rain water downpipe

Oslash19mm min

Oslash30mm

55 Electrical installation

DangerRisk of death from electric shock

The power supply terminals L and N remainlive even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

Only qualified electricians may carry out the electrical install-ation

551 Opening the electronics box

B

B

A

Follow the instructions in the specified sequence

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 8: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

4 Set-up

8 Installation and maintenance instructions ENERGY 0020177746_03

Information on theidentification plate

Meaning

Read the instructions

GC no Gas council number

33 Functional elements Combination unit

15

12

11

10

8

9

7

5

6

4

3

2

1

18

17

20 19

14

16

13

1 Electronics box

2 Heating circuit expan-sion relief valve

3 Plate heat exchanger

4 Condensate siphon

5 Flue gas pipe

6 Pressure sensor

7 Flue gas analysis point(for rear flue gas con-nection)

8 Ignition transformer

9 Gas valve

10 Air intake pipe

11 Fan

12 Supply air measuringstub pipe (for upper fluegas connection)

13 Flue gas analysis point(for upper flue gasconnection)

14 Primary heat exchanger

15 Heating expansionvessel

16 Purge hose

17 Volume flow sensor

18 Heating pump

19 Bypass

20 3-way valve

34 CE label

ensp

The CE label shows that the products comply with the basicrequirements of the applicable directives as stated on theidentification plate

The declaration of conformity can be viewed at the manufac-turers site

4 Set-up

41 Transporting the unit

Important With regard to the regulations of 1992 concern-ing the manual handling of loads the unit exceeds theweight that can be lifted by a single person

411 General

Hold the load as close as possible to your body Avoidrotational movements Instead reposition your feet

If the unit is being lifted by two persons ensure yourmovements are coordinated during lifting

Avoid bending your upper body ndash do not lean forwards orto the side

Wear suitable non-slip protective gloves in order to pro-tect your hands against sharp edges Ensure that you arecarrying the load securely

If required get somebody to assist you in this

412 Unloading the box from the delivery van

It is recommended that two people lift the unit together

Lift the box using the straps provided

Use safe lifting techniques ndash keep your back straight andbend 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 yourmovements are coordinated during lifting

If required get somebody to assist you in this

42 Unpacking the product

1 Remove the product from its box

2 Remove the protective film from all of the productscomponents

43 Checking the scope of delivery

Check that the scope of delivery is complete and intact

Number Designation

1 Heat generator

1 Unit mounting bracket

1 Flexible condensate discharge pipe

6 34 seals

4 12 seals

1 Service valve

1 Gas stopcock

1 Filling device

Set-up 4

0020177746_03 ENERGY Installation and maintenance instructions 9

Number Designation

2 Connection pipe (heating flow and return)

1 Cold water connection pipe

1 Domestic hot water connection pipe

1 Gas pipe

1 Expansion relief valve discharge pipe

1 Mounting template

1 Enclosed documentation

44 Dimensions

96121

34

123185

390

12358 58

170

702

150

280

1 2 3 4 5

7

6

1 Heating flow

2 Hot water connection

3 Gas connection

4 Cold water connection

5 Heating return

6 Connection on the backof the airflue pipe

7 Connection on the topof the airflue pipe

45 Minimum clearances

CC

AB

D

Minimum clearance

A 150 mm (top airflue gas connection)

20 mm (airflue gas connection on the rear)

B 150 mm

C 5 mm

(70 mm if the side panels ought to be removed)

D 600 mm

It is not necessary to maintain a clearance between theproduct and components made of combustible materials thatgo beyond the minimum clearances

46 Using the mounting template

Use the mounting template to ascertain the locations atwhich you need to drill holes

47 Wall-mounting the product

Note

If you are using the rear airflue gas connectioninstall the airflue pipe before you wall-mount theproduct

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the operational weight of the product

2 Check if the supplied fixing material may be used forthe wall

4 Set-up

10 Installation and maintenance instructions ENERGY 0020177746_03

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial 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 suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

Conditions The fixing material may not be used for the wall

Wall-mount the product as described using the permittedfixing material provided on-site

48 Removinginstalling the front casing

481 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

482 Installing the front casing

Refit the components in the reverse order

49 Removinginstalling the side section

491 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least70 mm) you can remove the side section to fa-cilitate maintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

492 Installing the side section

Refit the components in the reverse order

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 11

5 Installation

DangerRisk of scalding andor damage due toincorrect installation leading to escapingwater

Mechanical stresses in the connection pipesmay lead to leaks

Ensure that there is no mechanical stresswhen installing the connection pipes

CautionRisk of material damage caused byresidues in the pipelines

Welding remnants sealing residues dirt orother residues in the pipelines may damagethe product

Flush the heating installation thoroughlybefore installing the product

51 Checking the gas meter

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

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of material damage caused by corro-sion

Due to non-diffusion-tight plastic pipes in theheating installation air gets into the heatingwater Air in the heating water causes corro-sion in the heat generator circuit and in theproduct

If you use non-diffusion-tight plastic pipesin the heating installation ensure that noair gets into the heat generator circuit

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connectors if the connectorsare not yet screwed to the service valves

Note

Apply heat insulation to the water pipes to theboiler outlet and to the installation

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the installation

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return valve at the products outlet(heating flow)

2 Ensure that the installation has the following compon-ents

ndash A cold water stopcock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas pipe before start-up

3 Check whether the connections (rarr Page 20) are leak-tight

5 Installation

12 Installation and maintenance instructions ENERGY 0020177746_03

53 Connecting the drain pipework for theexpansion relief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The piping must be installed in such a way that youcan see when water drips out

54 Connecting the condensate discharge pipe

1

2

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

Use PVC or any other material that is suitable for drain-ing the non-neutralised condensate

If you cannot guarantee that the materials from which thedrain pipework is made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate traps (1) Use the supplied drainhose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burrs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

For any installation the condensate must be free flowingand not be possible for air back-pressure to prevent wa-ter flow

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat input below 70 kW

541 Condensate drainage systems

5411 Internal soil and vent pipe

Oslash19mm min

5412 External soil and vent pipe

L = 3m max

Oslash19mm min

Oslash30mm

5413 External termination into a gulley or hopper

L = 3m max

Oslash19mm min

Oslash30mm

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 13

5414 Internal termination into combined sinkwaste

Oslash30mm

Oslash19mm min

5415 Internal termination downstream of sinkwaste

Oslash30mm

Oslash19mm min

5416 External termination into soakaway

400m

m m

in

300m

m m

in25

mm

min

500mm min

Oslash100mm

L = 3m max

Oslash19mm min

Oslash30mm

5417 External termination into rain water downpipe

Oslash19mm min

Oslash30mm

55 Electrical installation

DangerRisk of death from electric shock

The power supply terminals L and N remainlive even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

Only qualified electricians may carry out the electrical install-ation

551 Opening the electronics box

B

B

A

Follow the instructions in the specified sequence

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 9: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Set-up 4

0020177746_03 ENERGY Installation and maintenance instructions 9

Number Designation

2 Connection pipe (heating flow and return)

1 Cold water connection pipe

1 Domestic hot water connection pipe

1 Gas pipe

1 Expansion relief valve discharge pipe

1 Mounting template

1 Enclosed documentation

44 Dimensions

96121

34

123185

390

12358 58

170

702

150

280

1 2 3 4 5

7

6

1 Heating flow

2 Hot water connection

3 Gas connection

4 Cold water connection

5 Heating return

6 Connection on the backof the airflue pipe

7 Connection on the topof the airflue pipe

45 Minimum clearances

CC

AB

D

Minimum clearance

A 150 mm (top airflue gas connection)

20 mm (airflue gas connection on the rear)

B 150 mm

C 5 mm

(70 mm if the side panels ought to be removed)

D 600 mm

It is not necessary to maintain a clearance between theproduct and components made of combustible materials thatgo beyond the minimum clearances

46 Using the mounting template

Use the mounting template to ascertain the locations atwhich you need to drill holes

47 Wall-mounting the product

Note

If you are using the rear airflue gas connectioninstall the airflue pipe before you wall-mount theproduct

1 Check whether the wall has sufficient load-bearing ca-pacity to bear the operational weight of the product

2 Check if the supplied fixing material may be used forthe wall

4 Set-up

10 Installation and maintenance instructions ENERGY 0020177746_03

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial 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 suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

Conditions The fixing material may not be used for the wall

Wall-mount the product as described using the permittedfixing material provided on-site

48 Removinginstalling the front casing

481 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

482 Installing the front casing

Refit the components in the reverse order

49 Removinginstalling the side section

491 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least70 mm) you can remove the side section to fa-cilitate maintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

492 Installing the side section

Refit the components in the reverse order

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 11

5 Installation

DangerRisk of scalding andor damage due toincorrect installation leading to escapingwater

Mechanical stresses in the connection pipesmay lead to leaks

Ensure that there is no mechanical stresswhen installing the connection pipes

CautionRisk of material damage caused byresidues in the pipelines

Welding remnants sealing residues dirt orother residues in the pipelines may damagethe product

Flush the heating installation thoroughlybefore installing the product

51 Checking the gas meter

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

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of material damage caused by corro-sion

Due to non-diffusion-tight plastic pipes in theheating installation air gets into the heatingwater Air in the heating water causes corro-sion in the heat generator circuit and in theproduct

If you use non-diffusion-tight plastic pipesin the heating installation ensure that noair gets into the heat generator circuit

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connectors if the connectorsare not yet screwed to the service valves

Note

Apply heat insulation to the water pipes to theboiler outlet and to the installation

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the installation

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return valve at the products outlet(heating flow)

2 Ensure that the installation has the following compon-ents

ndash A cold water stopcock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas pipe before start-up

3 Check whether the connections (rarr Page 20) are leak-tight

5 Installation

12 Installation and maintenance instructions ENERGY 0020177746_03

53 Connecting the drain pipework for theexpansion relief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The piping must be installed in such a way that youcan see when water drips out

54 Connecting the condensate discharge pipe

1

2

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

Use PVC or any other material that is suitable for drain-ing the non-neutralised condensate

If you cannot guarantee that the materials from which thedrain pipework is made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate traps (1) Use the supplied drainhose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burrs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

For any installation the condensate must be free flowingand not be possible for air back-pressure to prevent wa-ter flow

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat input below 70 kW

541 Condensate drainage systems

5411 Internal soil and vent pipe

Oslash19mm min

5412 External soil and vent pipe

L = 3m max

Oslash19mm min

Oslash30mm

5413 External termination into a gulley or hopper

L = 3m max

Oslash19mm min

Oslash30mm

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 13

5414 Internal termination into combined sinkwaste

Oslash30mm

Oslash19mm min

5415 Internal termination downstream of sinkwaste

Oslash30mm

Oslash19mm min

5416 External termination into soakaway

400m

m m

in

300m

m m

in25

mm

min

500mm min

Oslash100mm

L = 3m max

Oslash19mm min

Oslash30mm

5417 External termination into rain water downpipe

Oslash19mm min

Oslash30mm

55 Electrical installation

DangerRisk of death from electric shock

The power supply terminals L and N remainlive even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

Only qualified electricians may carry out the electrical install-ation

551 Opening the electronics box

B

B

A

Follow the instructions in the specified sequence

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 10: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

4 Set-up

10 Installation and maintenance instructions ENERGY 0020177746_03

Conditions The load-bearing capacity of the wall is sufficient The fixingmaterial 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 suf-ficient load-bearing capacity Use individual stands orprimary walling for example

Do not wall-mount the product if you cannot providewall-mounting apparatus with a sufficient load-bearingcapacity

Conditions The fixing material may not be used for the wall

Wall-mount the product as described using the permittedfixing material provided on-site

48 Removinginstalling the front casing

481 Removing the front casing

B

C

A

1

1

1 Undo the two screws (1)

2 Gently press the front casing backwards in the centreso that the latching lug is released

3 Pull the front casing forwards at the bottom edge

4 Lift the front casing upwards from the bracket

482 Installing the front casing

Refit the components in the reverse order

49 Removinginstalling the side section

491 Removing the side section

CautionRisk of material damage caused by mech-anical deformation

Removing both side sections may causemechanical distortion in the product whichmay cause damage to the piping for ex-ample and potentially result in leaks

Always remove only one side section ndashnever both side sections at the same time

Note

If there is sufficient lateral clearance (at least70 mm) you can remove the side section to fa-cilitate maintenance or repair work

2x 1

A

B

C

D

1 Tilt the electronics box forward

2 Hold on to the side section so that it cannot fall andunscrew both screws (1) one from the top and onefrom the bottom

3 Tilt the side section to the outside and move it down-wards and out

492 Installing the side section

Refit the components in the reverse order

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 11

5 Installation

DangerRisk of scalding andor damage due toincorrect installation leading to escapingwater

Mechanical stresses in the connection pipesmay lead to leaks

Ensure that there is no mechanical stresswhen installing the connection pipes

CautionRisk of material damage caused byresidues in the pipelines

Welding remnants sealing residues dirt orother residues in the pipelines may damagethe product

Flush the heating installation thoroughlybefore installing the product

51 Checking the gas meter

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

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of material damage caused by corro-sion

Due to non-diffusion-tight plastic pipes in theheating installation air gets into the heatingwater Air in the heating water causes corro-sion in the heat generator circuit and in theproduct

If you use non-diffusion-tight plastic pipesin the heating installation ensure that noair gets into the heat generator circuit

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connectors if the connectorsare not yet screwed to the service valves

Note

Apply heat insulation to the water pipes to theboiler outlet and to the installation

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the installation

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return valve at the products outlet(heating flow)

2 Ensure that the installation has the following compon-ents

ndash A cold water stopcock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas pipe before start-up

3 Check whether the connections (rarr Page 20) are leak-tight

5 Installation

12 Installation and maintenance instructions ENERGY 0020177746_03

53 Connecting the drain pipework for theexpansion relief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The piping must be installed in such a way that youcan see when water drips out

54 Connecting the condensate discharge pipe

1

2

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

Use PVC or any other material that is suitable for drain-ing the non-neutralised condensate

If you cannot guarantee that the materials from which thedrain pipework is made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate traps (1) Use the supplied drainhose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burrs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

For any installation the condensate must be free flowingand not be possible for air back-pressure to prevent wa-ter flow

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat input below 70 kW

541 Condensate drainage systems

5411 Internal soil and vent pipe

Oslash19mm min

5412 External soil and vent pipe

L = 3m max

Oslash19mm min

Oslash30mm

5413 External termination into a gulley or hopper

L = 3m max

Oslash19mm min

Oslash30mm

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 13

5414 Internal termination into combined sinkwaste

Oslash30mm

Oslash19mm min

5415 Internal termination downstream of sinkwaste

Oslash30mm

Oslash19mm min

5416 External termination into soakaway

400m

m m

in

300m

m m

in25

mm

min

500mm min

Oslash100mm

L = 3m max

Oslash19mm min

Oslash30mm

5417 External termination into rain water downpipe

Oslash19mm min

Oslash30mm

55 Electrical installation

DangerRisk of death from electric shock

The power supply terminals L and N remainlive even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

Only qualified electricians may carry out the electrical install-ation

551 Opening the electronics box

B

B

A

Follow the instructions in the specified sequence

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 11: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 11

5 Installation

DangerRisk of scalding andor damage due toincorrect installation leading to escapingwater

Mechanical stresses in the connection pipesmay lead to leaks

Ensure that there is no mechanical stresswhen installing the connection pipes

CautionRisk of material damage caused byresidues in the pipelines

Welding remnants sealing residues dirt orother residues in the pipelines may damagethe product

Flush the heating installation thoroughlybefore installing the product

51 Checking the gas meter

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

52 Gas and water connections

CautionRisk of damage caused by incorrect gasconnection installation

Excess test pressure or operating pressuremay cause damage to the gas valve

Check the leak-tightness of the gas valveusing a maximum pressure of 11 kPa(110 mbar)

CautionRisk of material damage caused by corro-sion

Due to non-diffusion-tight plastic pipes in theheating installation air gets into the heatingwater Air in the heating water causes corro-sion in the heat generator circuit and in theproduct

If you use non-diffusion-tight plastic pipesin the heating installation ensure that noair gets into the heat generator circuit

CautionRisk of material damage due to heat trans-fer during soldering

Only solder connectors if the connectorsare not yet screwed to the service valves

Note

Apply heat insulation to the water pipes to theboiler outlet and to the installation

Preliminary work1 Check that the system volume and the volumetric capa-

city of the expansion vessel are compatible

If the volume of the expansion vessel is insufficientfor the installation

Install an additional expansion vessel in theheating return as close to the product as pos-sible

Install a non-return valve at the products outlet(heating flow)

2 Ensure that the installation has the following compon-ents

ndash A cold water stopcock for the unit

ndash A gas stopcock for the unit

ndash A filling and draining device in the heating installa-tion

12

34

5

1 Heating flow connec-tion G34

2 Hot water connectionG34

3 Gas connection G12

4 Connection for the coldwater supply line G34

5 Heating return connec-tion G34

1 Connect the water and gas connections in accordancewith the applicable standards

2 Purge the gas pipe before start-up

3 Check whether the connections (rarr Page 20) are leak-tight

5 Installation

12 Installation and maintenance instructions ENERGY 0020177746_03

53 Connecting the drain pipework for theexpansion relief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The piping must be installed in such a way that youcan see when water drips out

54 Connecting the condensate discharge pipe

1

2

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

Use PVC or any other material that is suitable for drain-ing the non-neutralised condensate

If you cannot guarantee that the materials from which thedrain pipework is made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate traps (1) Use the supplied drainhose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burrs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

For any installation the condensate must be free flowingand not be possible for air back-pressure to prevent wa-ter flow

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat input below 70 kW

541 Condensate drainage systems

5411 Internal soil and vent pipe

Oslash19mm min

5412 External soil and vent pipe

L = 3m max

Oslash19mm min

Oslash30mm

5413 External termination into a gulley or hopper

L = 3m max

Oslash19mm min

Oslash30mm

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 13

5414 Internal termination into combined sinkwaste

Oslash30mm

Oslash19mm min

5415 Internal termination downstream of sinkwaste

Oslash30mm

Oslash19mm min

5416 External termination into soakaway

400m

m m

in

300m

m m

in25

mm

min

500mm min

Oslash100mm

L = 3m max

Oslash19mm min

Oslash30mm

5417 External termination into rain water downpipe

Oslash19mm min

Oslash30mm

55 Electrical installation

DangerRisk of death from electric shock

The power supply terminals L and N remainlive even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

Only qualified electricians may carry out the electrical install-ation

551 Opening the electronics box

B

B

A

Follow the instructions in the specified sequence

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 12: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

5 Installation

12 Installation and maintenance instructions ENERGY 0020177746_03

53 Connecting the drain pipework for theexpansion relief valve

1

Ensure that the pipeline is visible

The pipe must have a continuous fall and be routed to aposition so that any discharge of water possibly boilingor steam cannot create any danger to persons damageto property or external electrical components and wiring

◁ The piping must be installed in such a way that youcan see when water drips out

54 Connecting the condensate discharge pipe

1

2

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

Use PVC or any other material that is suitable for drain-ing the non-neutralised condensate

If you cannot guarantee that the materials from which thedrain pipework is made are suitable install a system forneutralising the condensate

Note

The condensate drain pipework must have acontinuous fall (45 mm per metre) and shouldwhenever possible terminate at a suitabledrain point within the heated envelope of thebuilding that will remain frost free under longperiods of low external temperatures

Connect the condensate traps (1) Use the supplied drainhose (2) for this

Connect a condensate discharge pipe (215 mm notincluded in the scope of delivery) to the drain hose (2)

During installation remove all burrs from inside of cut pipework and avoid excessive adhesive which may trap smallpockets of water close to the pipe wall which can freezeand build into a larger ice plug

For any installation the condensate must be free flowingand not be possible for air back-pressure to prevent wa-ter flow

As with other pipe work insulate the condensate dis-charge pipe to minimise any risk of freezing and bewarewhen crossing cavities that the fall is maintained and thepipe sleeved

You can find further information in specification BS 6798for installing and maintaining gas-fired boilers with a nominalheat input below 70 kW

541 Condensate drainage systems

5411 Internal soil and vent pipe

Oslash19mm min

5412 External soil and vent pipe

L = 3m max

Oslash19mm min

Oslash30mm

5413 External termination into a gulley or hopper

L = 3m max

Oslash19mm min

Oslash30mm

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 13

5414 Internal termination into combined sinkwaste

Oslash30mm

Oslash19mm min

5415 Internal termination downstream of sinkwaste

Oslash30mm

Oslash19mm min

5416 External termination into soakaway

400m

m m

in

300m

m m

in25

mm

min

500mm min

Oslash100mm

L = 3m max

Oslash19mm min

Oslash30mm

5417 External termination into rain water downpipe

Oslash19mm min

Oslash30mm

55 Electrical installation

DangerRisk of death from electric shock

The power supply terminals L and N remainlive even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

Only qualified electricians may carry out the electrical install-ation

551 Opening the electronics box

B

B

A

Follow the instructions in the specified sequence

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 13: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Installation 5

0020177746_03 ENERGY Installation and maintenance instructions 13

5414 Internal termination into combined sinkwaste

Oslash30mm

Oslash19mm min

5415 Internal termination downstream of sinkwaste

Oslash30mm

Oslash19mm min

5416 External termination into soakaway

400m

m m

in

300m

m m

in25

mm

min

500mm min

Oslash100mm

L = 3m max

Oslash19mm min

Oslash30mm

5417 External termination into rain water downpipe

Oslash19mm min

Oslash30mm

55 Electrical installation

DangerRisk of death from electric shock

The power supply terminals L and N remainlive even if the product is switched off

Switch off the power supply Secure the power supply against being

switched on again

Only qualified electricians may carry out the electrical install-ation

551 Opening the electronics box

B

B

A

Follow the instructions in the specified sequence

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 14: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

5 Installation

14 Installation and maintenance instructions ENERGY 0020177746_03

552 Closing the electronics box

Follow the instructions in the reverse order

553 Cable route

1

2

1 24-V eBUS cable route 2 230-V eBUS cable route

554 Carrying out the wiring

30 mm max

1 Shorten the connection cables to the appropriatelengths to prevent them from causing damage insidethe electronics box

2 Screw the plug to the connection cable

3 Plug the plug into the slot provided on the PCB

555 Establishing the power supply

1

1 Observe all valid regulations

2 Make sure that the rated voltage of the mains is 230 V

3 Provide one common electricity supply for the boilerand for the corresponding controller

ndash Power supply Single-phase 230 V 50 Hz

ndash Fuse protection le 3 A

4 Open the electronics box (rarr Page 13)

5 Observe the routing of the power supply cable (1) in theelectronics box in order to guarantee that there is nostrain

le 30

mm

NL X1230V~

RT

6 Carry out the wiring (rarr Page 14)

7 Close the electronics box (rarr Page 14)

8 Screw the supplied plug to a three-core power supplycable that complies with the relevant standards

9 Connect the plug for the power supply cable

10 Make sure that access to the power supply is alwaysfreely available and is not covered or blocked by anobstruction

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 15: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Operation 6

0020177746_03 ENERGY Installation and maintenance instructions 15

556 Connecting controllers to the electronicsystem

X2

X22 X41

ndash +24V=RT BUS

BurneroffX

106

BUS24 V

BU

SR

TB

off

Burner

offR

T24V

=-

+B

US

1

4

32

1 Safety thermostat forfloor-standing heating

2 24 V controller

3 eBUS controller or radioreceiver unit

4 Outside temperaturesensor wired

1 Open the electronics box (rarr Page 13)

2 Carry out the wiring (rarr Page 14)

3 Connect the individual components depending on thetype of installation

Conditions If installing a multi-circuit controller

Change the pump operating mode (d18) from Eco (in-termittent pump operating mode) to Comfort (continuouspump operating mode)

Conditions If you are connecting a controller (230 V)

le 30

mm

NL X1230V~

RT

Connect the controller to the main plug

Remove the bridge from the plug 24V=RT

4 Close the electronics box

6 Operation

61 Using diagnostics codes

You can use the parameters marked as adjustable in thetable of diagnostics codes to adapt the product to the systemand customer requirements

Overview of diagnostics codes (rarr Page 30)

611 Activating diagnostics codes

1 Press and hold the button for 7 seconds

◁ is shown in the display

2 Press the or button to set the value

◁ The access code (96) is reserved for the competentperson

◁ The access code (35) is reserved for the customerservice

3 Press the button to confirm

◁ is shown in the display

612 Setting a diagnostics code

1 Press the or button to select the diagnosticscode

2 Press the button to confirm

◁ The value andor status of the diagnostics code isshown in the display

3 Press the or button to set the value

4 If you allow the value to flash for three seconds thesetting is automatically confirmed

◁ is shown in the display for 1 second

Note

You can manually confirm the setting at anytime by pressing and holding the buttonfor less than 3 seconds

5 Proceed accordingly for all parameters that need to bechanged

6 Press and hold the button for 3 seconds to finishconfiguring the diagnostics codes

◁ The display switches to the basic display

62 Displaying the status codes

The status codes display the products current operatingstatus

Status codes ndash Overview (rarr Page 34)

621 Activating the status codes display

1 Hold the button down for more than 7 seconds

◁ SXX is shown on the display followed by the heat-ing flow temperature the internal system pressureand the cylinder temperature (depending on the ver-sion)

2 Press the button to exit this menu

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 16: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

7 Start-up

16 Installation and maintenance instructions ENERGY 0020177746_03

◁ The display switches to the basic display

63 Using check programmes

By activating various check programmes you can triggervarious special functions on the product

Check programmes ndash Overview (rarr Page 30)

631 Calling up the check programmes

1 Hold the button down for more than 5 seconds

◁ All symbols are shown in the display

◁ is shown in the display

2 Press and hold the button for five seconds

◁ is shown in the display

3 Press the or button to select the checkprogramme

4 Press the button to confirm

◁ on is shown in the display and the programmestarts

5 Press the and buttons at the same time whilstrunning a check programme

◁ The heating water temperature and the filling pres-sure for the heating installation are shown altern-ately in the display

6 Press the button to return to the check programme

◁ The display shows the check programme

7 Press the button to finish the check programme

◁ OFF is shown in the display

8 Press and hold the button for 3 seconds to finishthe check programmes

◁ End is shown in the display

◁ The display switches to the basic display

Note

If you do not press any button for 15 minutesthe current programme is automatically can-celled and the basic display is shown

632 Displaying the pressure and temperature ofthe heating during a check programme

1 Press the buttons simultaneously

◁ Display the filling pressure in the heating installation

◁ Display the heating flow temperature

2 Press the button to display the check programmecurrently running

7 Start-up

71 Carrying out the initial start-up

Initial start-up must be carried out by a customer servicetechnician or an authorised competent person using the first-commissioning-checklist The first-commissioning-checklistin the appendix (rarr Page 42) of the installation instructionsmust be filled out and stored carefully along with the unitsdocumentation

Carry out the initial start-up using the first-commission-ing-checklist in the appendix

Fill out and sign the first-commissioning-checklist

72 Checking the type of gas

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

Check the type of gas as part of routine product mainten-ance work when replacing components or carrying outwork on the gas route

73 Checking the factory setting

The products combustion has been factory tested and ispreset for operation with the gas group indicated on the iden-tification plate

The product is only authorised to be operated with naturalgas

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

Conditions The product design is not compatible with the local gasgroup

Do not start up the product

Conditions The product design is compatible with the local gas group

Proceed as described below

74 Checking and treating the heatingwaterfilling and supplementary water

CautionRisk of material damage due to poor-qual-ity heating water

Ensure that the heating water is of suffi-cient quality

Before filling or topping up the installation check thequality 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 materialsyou must desludge the installation

Use a magnetic rod to check whether it contains mag-netite (iron oxide)

If you ascertain that it contains magnetite clean the in-stallation and apply suitable corrosion-protection meas-ures or fit a magnetic filter

Check the pH value of the removed water at 25 degC

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 17: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 17

If the value is below 65 or above 85 clean the systemand treat the heating water

Ensure that oxygen cannot get into the heating water

Checking the filling and supplementary water Before filling the installation 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 supplementarywater

Provided the national regulations and technical standardsdo not stipulate more stringent requirements the followingapplies

You must treat the heating water in the following cases

ndash If the entire filling and supplementary water quantity dur-ing the operating life of the system exceeds three timesthe nominal volume of the heating installation or

ndash If the guideline values listed in the following table are notmet or

ndash if the pH value of the heating water is less than 65 ormore than 85

Totalheatingoutput

Water hardness at specific system volume1)

le 20 lkWgt 20 lkWle 50 lkW

gt 50 lkW

kWppm

CaCO₃molmsup3

ppmCaCO₃

molmsup3

ppmCaCO₃

molmsup3

lt 50 lt 300 lt 3 200 2 2 002

gt 50to le 200

200 2 150 15 2 002

gt 200to le 600

150 15 2 002 2 002

gt 600 2 002 2 002 2 002

1) Nominal capacity in litresheating output in the case of multi-boiler systems the smallest single heating output is to be used

CautionThe use of unsuitable heating water maycause aluminium corrosion and a result-ing lack of leak-tightness

In contrast to steel grey cast iron or copperfor example aluminium reacts with alkalineheating water (pH value gt 85) to producesubstantial corrosion

When using aluminium make sure thatthe pH value of the heating water isbetween 65 and a maximum of 85

CautionRisk of material damage if the heatingwater is treated with unsuitable additives

Unsuitable additives may cause changes inthe components noises in heating mode andpossibly subsequent damage

Do not use any unsuitable frost and cor-rosion protection agents biocides or seal-ants

No incompatibility with our products has been detected todate with proper use of the following additives

When using additives follow the manufacturers instruc-tions without exception

We accept no liability for the compatibility of any additive orits effectiveness in the rest of the heating system

Additives for cleaning measures (subsequentflushing required)ndash Adey MC3+

ndash Adey MC5

ndash Fernox F3

ndash Sentinel X 300

ndash Sentinel X 400

Additives intended to remain permanently in theinstallationndash Adey MC1+

ndash Fernox F1

ndash Fernox F2

ndash Sentinel X 100

ndash Sentinel X 200

Additives for frost protection intended to remainpermanently in the installationndash Adey MC ZERO

ndash Fernox Antifreeze Alphi 11

ndash Sentinel X 500

If you have used the above-mentioned additives informthe end user about the measures that are required

Inform the end user about the measures required for frostprotection

75 Avoiding danger arising from insufficientwater pressure

The filling pressure must be between 010 and 015 MPa(10 and 15 bar)

Note

If the heating flow temperature is shown in thedisplay press and hold the and buttonsat the same time for longer than five seconds ortemporarily deactivate heating mode in order todisplay the pressure

If the heating installation extends over several storeyshigher filling pressures may be required to avoid air enteringthe heating installation

If the water pressure falls below 005 MPa (05 bar) thevalue flashes in the display

If the water pressure falls below 003 MPa (03 bar) theproduct switches off The display shows 00 MPa (00 bar)Fault F22 will be stored in the fault list

Top up the water in the heating installation to start up theproduct again

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 18: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

7 Start-up

18 Installation and maintenance instructions ENERGY 0020177746_03

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

76 Switching on the product

Switch on the product via the main switch installed on-site

77 Filling and purging the heating installation

Preliminary work Flush the heating installation through

1

1

1 Check the silicone hose connection (1) between thepumps automatic air vent and the hydraulic console

2 Fill with water until the required filling pressure isreached

ndash Recommended filling pressure 1 hellip 15 bar

◁ The heating and hot water functions cannot be activ-ated

◁ The pressure value flashes in the display until apressure of 005 MPa (05 bar) or higher has beenreached

◁ An automatic air vent function is activated if thepressure exceeds 005 MPa (05 bar) for longer than15 seconds

3 Purge each radiator until the water escapes normallyand then retighten the systems purging valves

4 Check whether all connections are leak-tight

Conditions If the noise persists in the boiler

Purge the product again by activating check programme(P07) and then (P06)

Check programmes ndash Overview (rarr Page 30)

78 Filling the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

4 Re-insert the float (3)

Note

Check that the float is present in the con-densate siphon

5 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

79 Filling the hot water circuit

1 Open the water tap to fill the hot water circuit

2 Close the water tap once the appropriate volume ofwater has flowed out

◁ The hot water circuit is filled

3 Check all connections and the entire system for leak-tightness

710 Checking and adjusting the gas settings

Only a qualified competent person is authorised to imple-ment the settings on the gas valve assembly

Each destroyed tamper-proof seal must be replaced

The CO₂ adjusting screw must be sealed

Never modify the factory setting of the gas pressure regu-lator of the gas valve assembly

7101 Checking the gas flow rate

The gas flow rate has been set during production and doesnot require adjustment With the front casing fitted check thegas flow rate of the boiler as follows

Start up the product with the check programme P01

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
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Page 19: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Start-up 7

0020177746_03 ENERGY Installation and maintenance instructions 19

In addition ensure that maximum heat can be dissipatedinto the heating system by turning up the room thermo-stat

Wait at least 5 minutes until the boiler has reached itsoperating temperature

Ensure that all other gas appliances in the property areturned off

Measure the gas flow rate at the gas meter

Compare the measured values with the correspondingvalues in the table

Qnw from the dataplate

H gas in msup3h

Nom +5 minus10

153 162 170 146

184 195 205 176

247 261 274 235

257 272 286 245

286 303 318 273

306 324 340 292

357 378 397 340

Conditions Gas flow rate not in the permissible range

Check all of the piping and ensure that the gas flow ratesare correct

Only put the product into operation once the gas flowrates have been corrected

Conditions Gas flow rate in the permissible range

End the check programme P01

Allow the boiler to cool down by allowing pump overrun tooperate for a minimum of 2 minutes

Record the boiler maximum gas flow rate onto theBenchmark gas boiler commissioning checklist

7102 Checking the gas connection pressure (gasflow pressure)

1

2

1 Ensure that the gas inlet working pressure can beobtained with all other gas appliances in the propertyworking

2 Close the gas stopcock (1)

3 Undo the sealing screw on the test nipple (2)

4 Connect a manometer to the test nipple (2)

5 Open the gas stopcock (1)

6 Start up the product with check programme P01 (in-stallation with eBUS control)

7 In addition ensure that maximum heat can be dissip-ated by fully opening one or more hot water taps

8 With the boiler operating at full load check that the gasinlet working pressure at the reference test point (2)complies with the requirements

Permissible connection pressure

Great Bri-tain

Naturalgas

G20 17 hellip 2 kPa

(170hellip 20 mbar)

9 Should the pressure recorded at the reference test pointin the boiler be lower than indicated check if there isany blockage in the pipework or if the pipework is un-dersized

Conditions Gas flow pressure not in the permissible range

CautionRisk of material damage and operatingfaults caused by incorrect gas connec-tion pressureIf the gas connection pressure lies outsidethe permissible range this can cause oper-ating faults in and damage to the product Do not make any adjustments to the

product Do not start up the product

If you cannot correct the failure notify the gas supplycompany and proceed as follows

End check programme P01

Allow the boiler to cool down by allowing pump overrunto operate for a minimum of two minutes

Close the gas stopcock

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Close the gas stopcock (1)

Install the front casing (rarr Page 10)

Disconnect the product from the electrical installation

You must not start up the boiler

Conditions Gas flow pressure in the permissible range

End the check programme P01

Allow the boiler to cool down allowing pump overrun tooperate for a minimum of two minutes

Close the gas stopcock (1)

Remove the pressure gauge and retighten the sealingscrew (2) for the measuring nipple

Open the gas stopcock (1)

Check the test nipple for gas tightness

Install the front casing (rarr Page 10)

Reset boiler controls for normal operation

Record the appliance gas inlet working pressure (kParesp mbar) in the Benchmark gas boiler commissioningchecklist

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 20: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

7 Start-up

20 Installation and maintenance instructions ENERGY 0020177746_03

7103 Checking the leak-tightness of the flue gasinstallation and flue gas recirculation

1 Check the flue gas installation is intact in accordancewith the latest gas safe technical bulletin and informa-tion supplied in the installation instructions

2 For extended flue gas installations check for flue gasrecirculation using the air analysis point

3 Use a flue gas analyser

4 If you discover CO or CO2 in the supply air search forthe leak in the flue gas installation or for signs of fluegas recirculation

5 Eliminate the damage properly

6 Check again whether the supply air contains any CO orCO2

7 If you cannot eliminate the damage do not start up theproduct

7104 Thoroughly flushing the heating installation(hot)

1 Operate the appliance until the boiler and the heatingsystem are up to temperature

2 Check the heating system for leaks

3 Connect a hose to the drain valve located at the lowestposition of the heating system

4 Shut off the boiler open the drain valve and all purgevalves on the radiators and allow the water to flow outof the heating system and the boiler quickly and fully

5 Close the drain valve

6 Fill and purge the heating installation (rarr Page 18)

7 Re-fill the system until the system design pressure of01 MPa (10 bar) is attained

Note

The actual reading on the digital pressuregauge should ideally be 005 MPa (05 bar)plus an additional pressure correspondingto the highest point of the system above thebase of the boiler ndash 10 m head equals an ad-ditional 1 bar reading on the pressure gaugeThe minimum pressure should not be lessthan 01 MPa (1 bar) in any installation Ifthe system is to be treated with an inhibitor itshould be applied at this stage in accordancewith the manufacturerrsquos instructions Furtherinformation can be obtained from SentinelBetz Dearborn Ltd Tel 0151 420 9595 orFernox Alphandash Fry technologies Tel 08708700362

8 Install the front casing (rarr Page 10)

7105 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Inform Customer Service

711 Checking leak-tightness

Check the gas pipe the heating circuit and the hot watercircuit for leak-tightness

Check that the airflue pipe has been installed correctly

Conditions Room-sealed operation

Check whether the vacuum chamber has been closedtightly

7111 Checking the heating mode

1 Activate the heating mode on the user interface

2 Turn all thermostatic radiator valves on the radiatorsuntil they are fully open

3 Allow the product to operate for at least 15 minutes

4 Fill and purge the heating installation (rarr Page 18)

5 Activate the display for the current operating status(rarr Page 15)

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS04

7112 Checking the hot water generation

1 Activate the hot water handling mode on the userinterface

2 Open a hot water valve completely

3 Activate the display for the current operating status(rarr Page 15)

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 21: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Adapting the unit to the heating installation 8

0020177746_03 ENERGY Installation and maintenance instructions 21

Status codes ndash Overview (rarr Page 34)

◁ If the product is working correctly the display showsS14

8 Adapting the unit to the heatinginstallation

You can resetchange the system parameters (section Us-ing diagnostics codes)

Overview of diagnostics codes (rarr Page 30)

81 Burner anti-cycling time

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

811 Setting the maximum burner anti-cyclingtime

1 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

2 If required adjust the maximum burner anti-cycling timeusing the diagnostics code d02

812 Resetting the remaining burner anti-cyclingtime

Hold the button down for more than 3 seconds

◁ is shown in the display

82 Setting the pump output

The product is equipped with a speed-regulated high-effi-ciency pump which adjusts independently to the hydraulicconditions of the heating installation

If you have installed a low loss header in the heating install-ation you should switch off the speed regulation and set thepump output to a fixed value

If required change the setting of the pump speed whichdepends on the operating mode under diagnostics coded14

Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

Flow rate-pressure curves for 25 kW(pressure measured downstream of the valves)

A

B

0

10

20

30

40

50

60

0 200 400 600 800 1000 1200

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 30 kW(pressure measured downstream of the valves)

A

B

0102030405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

Flow rate-pressure curves for 35 kW(pressure measured downstream of the valves)

A

B

01020

30405060

0 200 400 600 800 1000 1200

70

1 2

34

1 Maximum speed (by-pass closed)

2 Maximum speed (de-fault setting for the by-pass)

3 Minimum speed (defaultsetting for the bypass)

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 22: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

9 Handing the product over to the end user

22 Installation and maintenance instructions ENERGY 0020177746_03

4 Flow rate at maximumoutput (ΔT = 20K)

A Throughput in circuit(lh)

B Available pressure(kPa)

83 Setting the bypass valve

CautionRisk of material damage caused by incor-rect setting of the high-efficiency pump

If the pressure at the bypass valve is in-creased (by turning it clockwise) and thepump output is set to less than 100 theproduct may not operate correctly

In this case set the pump output to5 = 100 using diagnostics parameterd14

Conditions d14 is set to 0 = auto

Do not change the factory settings

Conditions d14 is set to 1 - 5

Remove the front casing (rarr Page 10)

1

Regulate the pressure using the adjusting screw (1)

Position of the adjustingscrew

Notesapplication

Right-hand stop (screwedall the way in)

If the radiators do not heatup sufficiently at the defaultsetting In this case you mustset the pump to the maximumspeed

Mid-position (six anti-clockwise rotations)

Default setting

Five further anti-clockwiserotations starting from themid-position

If noises are produced in theradiators or radiator valves

Install the front casing (rarr Page 10)

84 Setting the hot water temperature

DangerRisk of death from legionella

Legionella multiply at temperatures below60 degC

Ensure that the end user is familiar withall of the Anti-legionella measures in orderto comply with the applicable regulationsregarding legionella prevention

Set the hot water temperature

Conditions Water hardness gt 357 molmsup3

ndash Hot water temperature le 50

9 Handing the product over to the enduser

When you have finished the installation attach the stickersupplied (in the end users language) to the productcover

Explain to the end user how the safety devices work andwhere they are located

Inform the end user how to handle the product

In particular draw attention to the safety informationwhich the end user must follow

Inform the end user that they must have the productmaintained in accordance with the specified intervals

Instruct the end user about measures taken for routingthe combustion air supply and flue system

10 Inspection and maintenance

101 Using original seals

If you replace components use only the enclosed originalseals additional sealing materials are not required

102 Observing inspection and maintenanceintervals

Adhere to the minimum inspection and maintenance in-tervals The inspection may require maintenance to becarried out earlier depending on the results

Inspection and maintenance work ndash Overview(rarr Page 39)

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 23: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 23

103 Procuring spare parts

The original components of the product were also certifiedby the manufacturer as part of the declaration of conformityIf you use other non-certified or unauthorised parts duringmaintenance or repair work this may void the conformity ofthe product and it will therefore no longer comply with theapplicable standards

We strongly recommend that you use original spare partsfrom the manufacturer as this guarantees fault-free and safeoperation of the product To receive information about theavailable original spare parts contact the contact addressprovided on the reverse of these instructions

If you require spare parts for maintenance or repairwork use only the spare parts that are permitted for theproduct

104 Checking the CO₂ content

1 Start up the product with the check programme (P01)and set the value

ndash Setting value for the programme P01 100

Check programmes ndash Overview (rarr Page 30)

2 Wait until the value that is read is stable

ndash Waiting period for reading a stable value 5 min

1

3 Unscrew the cover from the flue gas analysis point (1)

4 Measure the CO₂ content at the flue gas analysis point(1)

5 Compare the measured value with the correspondingvalue in the table

Checking the CO₂ content

Great Britain

front casing on front casing off

Natural gas

G20

92 plusmn1

◁ The value is OK

The value is not OK you cannot start up theproduct

Set the CO₂ content (rarr Page 23)

105 Setting the CO₂ content

Conditions The CO₂ content must be adjusted

1

A

B

Remove the sticker

Turn the screw (1) to set the CO₂ content (value withfront casing removed)

◁ To increase the CO₂ content Turn anti-clockwise

◁ To decrease the CO₂ content Turn clockwise

Only carry out the adjustment in increments of 18 turnand wait approximately 1 minute after each adjustmentuntil the value has stabilised

Compare the measured value with the correspondingvalue in the table

Setting the CO₂ value

Great Britain

front casing on front casingoff

Natural gas

G20

CO₂ at full load 92 plusmn02

Set for Wobbeindex W₀

1409 kWsdothmsup3

O₂ at full load 45 plusmn18 vol

CO at full load le 250 ppm

COCO₂ le 00027

If the setting is not in the specified adjustment rangeyou must not start up the product

Inform Customer Service

Check whether the air-quality requirements with regardto carbon monoxide are fulfilled

Fit the front panel

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 24: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

10 Inspection and maintenance

24 Installation and maintenance instructions ENERGY 0020177746_03

106 Removing the gas-air mixture unit

Note

The gas-air mixture unit consists of three maincomponents

ndash Fan

ndash Gas valve

ndash Burner cover

1 Switch off the product via the main switch

2 Close the gas isolator cock

3 Remove the front casing (rarr Page 10)

C

AB

1

D

2

4 Remove the screw (1)

5 Push the clip upwards

6 Remove the flue gas pipe (2)

3

4

5

AB

7 Remove the air intake pipe (3)

8 Remove the plugs from the gas valve (4) and from thefan (5)

A

C

D B

6

9 Remove the gas-air mixture unit (6)

7

7

8

10 Remove the burner seals (7) and the burner (8)

11 Check the burner and the heat exchanger for damageand dirt

12 If necessary clean or replace the components accord-ing to the following sections

13 Install the two new burner seals

107 Cleaning the heat exchanger

1

1 Protect the folded down electronics box against sprayedwater

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

◁ The water runs out into the condensate tray

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 25: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Inspection and maintenance 10

0020177746_03 ENERGY Installation and maintenance instructions 25

108 Checking the burner

1 Search the surface of the burner for possible damage Ifyou see any damage replace the burner

2 Install the two new burner seals

109 Checking the ignition electrode

1

2

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 combustionchamber

4 Check that the electrode ends (4) are undamaged

5 Check the electrode distance

ndash Clearance for the ignition electrodes 35 hellip 45 mm

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

If necessary replace the seal

1010 Cleaning the condensate siphon

C

2

3

1

AB

1 Unclip the lower section of the siphon (1) from the up-per section of the siphon (2)

2 Remove the float (3)

3 Flush out the float and lower section of the siphon withwater

4 Fill the lower section of the siphon with water up to 10mm below the upper edge of the condensate drain pipe-work

5 Reinsert the float (3)

Note

Check whether the float is present in thecondensate siphon

6 Clip the lower section of the siphon (1) into the uppersection of the siphon (2)

1011 Cleaning the filter in the cold water inlet

1 Close the main cold water supply line

2 Drain the product on the hot water side

3 Remove the connection piece from the connection forthe products cold water supply

4 Clean the filter in the cold water inlet without removingit

1012 Cleaning the heating filter

2

1

1 Remove the temperature sensor (1)

2 Remove the upper clip (2)

4

35

3 Remove the lower clip (3)

4 Remove the flow pipe (4)

5 Remove the heating filter (5) and clean it

6 Reinstall the components in the reverse order

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 26: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

11 Troubleshooting

26 Installation and maintenance instructions ENERGY 0020177746_03

1013 Installing the gas-air mixture unit

1 Install the burner

2 Install two new burner seals in the burner hood

3 Install the gas-air mixture unit

4 Tighten the screws on the gas-air mixture unit

ndash Ideally to 7 Nm if a torque spanner is available

5 Install the flue pipe

6 Install the air intake pipe

1014 Draining the product

1 Close the service valves of the product

2 Start check programme P05 (rarr Page 16)

Check programmes ndash Overview (rarr Page 30)

3 Open the drain cock

1015 Checking the admission pressure of theexpansion vessel

1 Measure the pre-charge pressure of the expansion ves-sel at the vessel valve

Conditions Pre-charge pressure lt 0075 MPa (075 bar)

Top up the expansion vessel in accordance with thestatic height of the heating installation ideally with ni-trogen otherwise with air Ensure that the drain valve isopen when topping up

2 If water escapes from the expansion vessels valve youmust replace the expansion vessel (rarr Page 28)

3 Fill and purge the heating installation (rarr Page 18)

1016 Completing inspection and maintenancework

1 Check the CO₂ content

1017 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

11 Troubleshooting

111 Rectifying faults

If fault codes (FXX) appear refer to the table in the ap-pendix or use the check programme(s)

Overview of fault codes (rarr Page 35)

Check programmes ndash Overview (rarr Page 30)

If several fault codes are generated at the same time theseare displayed alternately followed by the time at which therespective fault occurred

Hold the button down for more than 3 seconds

If you are unable to clear the fault code and it reappearsdespite several fault clearance attempts contact cus-tomer service

112 Calling up the fault memory

The last 10 fault codes are stored in the fault memory (to-gether with the time at which the respective fault occurredand after 24 hours with the number of days)

Hold the button down for more than 7 seconds

Overview of fault codes (rarr Page 35)

Press the button to exit this menu

113 Deleting the fault memory

1 Delete the fault memory using the diagnostics coded94

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

114 Resetting parameters to factory settings

1 Reset all parameters to the factory settings using thediagnostics code d96

2 Set the diagnostics code (rarr Page 15)

Overview of diagnostics codes (rarr Page 30)

115 Preparing the repair work

1 Switch off the product

2 Disconnect the product from the electrical installation

3 Remove the front casing

4 Close the gas stopcock

5 Close the service valves in the heating flow and in theheating return

6 Close the service valve in the cold water pipe

7 Drain the product if you want to replace water-bearingcomponents of the product

8 Ensure that water does not drip on live components(eg the electronics box)

9 Use only new seals and O-rings Do not use any addi-tional sealing materials

116 Replacing defective components

1161 Replacing the burner

1 Remove the gas-air mixture unit (rarr Page 24)

2 Remove the two burner seals

3 Remove the burner

4 Insert the new burner

5 Insert two new burner seals in the burner cover

6 Install the gas-air mixture unit (rarr Page 26)

1162 Replacing the gas-air mixture unit

1 Remove the gas-air mixture unit (rarr Page 24)

2 Install the new gas-air mixture (rarr Page 26)

1163 Replacing the heat exchanger

1 Remove the front casing (rarr Page 10)

2 Remove the gas-air mixture unit (rarr Page 24)

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 27: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Troubleshooting 11

0020177746_03 ENERGY Installation and maintenance instructions 27

1 A

B

3 Remove the gas pipe (1)

1

2

3

2 4

A

B

4 Remove the temperature sensor (3)

5 Remove the upper clip (1)

6 Remove the lower clip (4)

7 Remove the supply pipe (2)

2

2 3

B

1

A

8 Remove the upper clip (1)

9 Remove the lower clip (3)

10 Remove the return pipe (2)

1

A2

11 Remove the clip underneath the condensate tray (1)

12 Undo the four screws (2)

2

1

B

C

A

13 Remove the ignition electrode (1)

14 Lift the heat exchanger up slightly and remove it to-gether with the condensate tray

15 Remove the ignition transformer (2)

16 Install the new heat exchanger in reverse order

1164 Replacing the pump head

1

2

1 Disconnect the pump cable from the electronics box

2 Undo the four bolts (1)

3 Remove the pump head (2)

4 Replace the O-ring

5 Use four screws to secure the new pump head

6 Connect the pump cable to the electronics box

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 28: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

11 Troubleshooting

28 Installation and maintenance instructions ENERGY 0020177746_03

1165 Replacing the expansion vessel

B

C

1

2

3A

D

1 Undo the nut (3)

2 Remove both screws on the support plate (1)

3 Remove the support plate

4 Pull out the expansion vessel (2) towards the front

5 Insert the new expansion vessel into the product

6 Screw the new expansion vessel to the water connec-tion To do this use a new seal

7 Attach the support plate using both screws

8 Fill and purge the product (rarr Page 18) and if requiredthe heating installation

1166 Replacing the main PCB

C

C

D

B

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plugs

7 Close the electronics box

1167 Replacing the PCB for the user interface

B

C

C

D

A

A

1 Open the electronics box

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 thegroove at the bottom and into the clip at the top

6 Plug in the PCB plug

7 Close the electronics box

1168 Replacing the expansion relief valve

1

2

1 Remove the clip (2)

2 Remove the expansion relief valve

3 Fit the new expansion relief valve with a new O-ring

4 Reattach the clip (2)

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 29: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Decommissioning the product 12

0020177746_03 ENERGY Installation and maintenance instructions 29

1169 Replacing the volume flow sensor

1B

A

1 Pull out the plug

2 Remove the volume flow sensor (1)

3 Install the new volume flow sensor

4 Plug in the plug

11610 Replace the pressure sensor

1

2

1 Pull out the plug

2 Remove the clip (1)

3 Remove the pressure sensor (2)

4 Install the new pressure sensor

5 Reattach the clip (1)

117 Checking the product for leak-tightness

Check that the product is leak-tight (rarr Page 20)

12 Decommissioning the product

Switch off the product

Disconnect the product from the power mains

Close the gas isolator cock

Close the cold water stop cock

13 Customer service

For contact details for our customer service department youcan write to the address that is provided on the back pageor you can visit wwwglow-wormcouk

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 30: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

30 Installation and maintenance instructions ENERGY 0020177746_03

Appendix

A Check programmes ndash Overview

Note

Since the programme table is used for various products some programmes may not be visible for the product inquestion

Display Meaning

P01 Burner operation on adjustable heat input

The product operates after ignition with the heat input set between 0 (0 = Pmin) and 100 (100 = Pmax)

The function is active for 15 minutes

P02 Burner operation at ignition load

After ignition the product works at ignition load

The function is active for 15 minutes

P03 The product runs in heating mode with the maximum heat input set using diagnostics code d00

P04 Maximum output function

If there is a hot water request the product runs in hot water handling mode and at maximum heat load

If there is no hot water request the product runs with the heating partial load that is set via diagnostics coded00 and in heating mode

The function is active for 15 minutes

P05 Filling the product

The diverter valve moves to the mid-position The burner and pump switch off (to fill or drain the product)

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds the automatic purging function is activated

The function is active for 15 minutes

P06 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

P07 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

Automatic air ventfunction

Purging the product

If the pressure is lower than 003 MPa (03 bar) and then is above 005 MPa (05 bar) for longer than 15seconds 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

B Overview of diagnostics codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d00 Heating maximum output ndash ndash kW The maximum heating outputvaries depending on the product

rarr Section Technical data

Automatic Unit automaticallyadjusts the maximum output tothe current system demand

rarr SectionTechnical

data

Adjustable

d01 Pump overrun in heatingmode

1 60 min 1 5 Adjustable

d02 Maximum burner anti-cycling time in heatingmode

2 60 min 1 20 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 31: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 31

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d04 Water temperature in thecylinder

Current value ndash ndash Notadjustable

d05 Determined heating flowset target temperature

Current value ndash ndash Not

adjustable

d06 Hot water set target tem-perature

Current value (Combination unit only) ndash Notadjustable

d07 Set target temperaturefor the domestic hot wa-ter cylinder

Current value ndash ndash Notadjustable

d08 Status of the 230 V ther-mostat

Current value ndash 0 = Room thermostat open (noheat requirement)

1 = Room thermostat closed(heat requirement)

ndash Notadjustable

d09 Heating flow set targettemperature that is seton the eBUS room ther-mostat

Current value ndash ndash Notadjustable

d10 Status of the internalpump in the heating cir-cuit

Current value ndash off on ndash Notadjustable

d11 Status of the heatingcircuits shunt pump

Current value ndash off on ndash Notadjustable

d13 Status of the hot watercircuits circulation pump

Current value ndash off on ndash Notadjustable

d14 Operating mode of themodulating pump

0 5 ndash 0 = variable rotational speed(auto)

1 2 3 4 5 = Fixed rotationalspeeds rarr Section Setting thepump output

0 Adjustable

d15 Pump speed Current value ndash ndash Notadjustable

d16 Status of the 24 V roomthermostat

Current value ndash off = Heating off

on = Heating on

ndash Notadjustable

d17 Heating control ndash ndash ndash off = Flow temperature

on = Return temperature (ad-justment for underfloor heatingIf you have activated the returntemperature control the auto-matic heating output determina-tion function is not active)

0 Adjustable

d18 Pump overrun operatingmode

1 3 ndash 1 = Continuous (pump runs per-manently)

3 = Eco (intermittent pump modendash for the dissipation of the resid-ual heat after hot water gener-ation at an extremely low heatdemand)

1 Adjustable

d19 Pump operating mode 2stage pump

0 3 ndash 0 = Burner mode stage 2 pumpflowoverrun stage 1

1 = Heating mode and pumpflowoverrun stage 1 hot waterhandling mode stage 2

2 = Automatic heating modepump flowoverrun stage 1 hotwater handling mode stage 2

3 = Stage 2

3 Adjustable

d20 Maximum hot water settarget temperature

50 60 1 60 Adjustable

d21 Status of the warm startfor hot water

Current value ndash off = Function deactivated

on = Function activated andavailable

ndash Notadjustable

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 32: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

32 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d22 Status of the hot waterrequest

Current value ndash off = No current requirement

on = Current requirement

ndash Notadjustable

d23 Status of the heatingdemand

Current value ndash off = Heating off (Summer mode)

on = Heating on

ndash Notadjustable

d24 Status of the pressuremonitor

0 1 ndash off = Not switched

on = Switched

ndash Notadjustable

d25 Status of the requirementto reheat the cylinder orfor the hot water warmstart from the eBUS ther-mostat

Current value ndash off = Function deactivated

on = Function activated

ndash Notadjustable

d27 Function of relay 1(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

1 Adjustable

d28 Function of relay 2(multi-functional module)

1 10 ndash 1 = Circulation pump

2 = External pump

3 = Cylinder charging pump

4 = Extractor hood

5 = External solenoid valve

6 = Fault display

7 = Solar pump (omitted)

8 = eBUS remote control

9 = Legionella protection pump

10 = Solar valve

2 Adjustable

d31 Automatic filling device 0 2 ndash 0 = Manual

1 = Semi-automatic

2 = Automatic

0 Adjustable

d33 Fan speed target value Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d34 Value for the fan speed Current value rpm Fan speed = Display value x 100 ndash Notadjustable

d35 Position of the divertervalve

Current value ndash 0 = Heating

40 = Mid-position (parallel opera-tion)

100 = Domestic hot water

ndash Notadjustable

d36 Value for the hot waterflow

Current value lmin ndash ndash Notadjustable

d39 Water temperature in thesolar circuit

Current value ndash ndash Notadjustable

d40 Heating flow temperature Current value ndash ndash Notadjustable

d41 Heating return temperat-ure

Current value ndash ndash Notadjustable

d43 Heating curve 02 4 ndash 01 12 Adjustable

d45 Value for the base pointof the heating curve

15 30 ndash 1 20 Adjustable

d47 Outside temperature Current value ndash ndash Notadjustable

d50 Correction of the min-imum fan speed

0 3000 rpm 1

Fan speed = Display value x 10

600 Adjustable

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 33: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 33

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d51 Correction of the max-imum fan speed

-2500 0 rpm 1

Fan speed = Display value x 10

-1000 Adjustable

d58 Solar circuit reheating 0 3 ndash 0 = Boilers Legionella protectionfunction deactivated

3 = Hot water activated (mintarget value 60 degC)

0 Adjustable

d60 Number of blocks by thetemperature limiter

Current value ndash ndash ndash Notadjustable

d61 Number of unsuccessfulignitions

Current value ndash ndash ndash Notadjustable

d62 Night set-back 0 30 ndash 1 0 Adjustable

d64 Average burner ignitiontime

Current value s ndash ndash Notadjustable

d65 Maximum burner ignitiontime

Current value s ndash ndash Notadjustable

d66 Activation of the warmstart function for hot wa-ter

ndash ndash ndash off = Function deactivated

on = Function activated

1 Adjustable

d67 Remaining burner anti-cycling time (setting un-der d02)

Current value min ndash ndash Notadjustable

d68 Number of unsuccessfulignitions at 1st attempt

Current value ndash ndash ndash Notadjustable

d69 Number of unsuccessfulignitions at 2nd attempt

Current value ndash ndash ndash Notadjustable

d70 Operation of the divertervalve

0 2 ndash 0 = Normal operating mode(DHW and heating mode)

1 = Mid-position (parallel opera-tion)

2 = Permanent heating modeposition

0 Adjustable

d71 Maximum heating flowset target temperature

45 80 1 rarr SectionTechnical

data

Adjustable

d73 Correction of the hot wa-ter warm start temperat-ure

-15 5 K 1 0 Adjustable

d75 Maximum cylinder re-heating time

20 90 min 1 45 Adjustable

d77 Max cylinder reheating ndash ndash kW 1

rarr Section Technical data

ndash Adjustable

d80 Running time in heatingmode

Current value h Running time = Display value x100

ndash Notadjustable

d81 Running time in hot wa-ter handling mode

Current value h Running time = Display value x100

ndash Notadjustable

d82 Number of burner igni-tions in heating mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d83 Number of burner igni-tions in hot water hand-ling mode

Current value ndash Number of ignitions = Displayvalue x 100

ndash Notadjustable

d84 Maintenance in 0 3000 h Number of hours = Display valuex 10

300 Notadjustable

d85 Increase in the min out-put (heating and hot wa-ter handling mode)

ndash ndash kW 1 ndash Adjustable

d88 Flow rate limit valuefor ignition in hot waterhandling mode

0 1 ndash 0 = 17 lmin (no delay)

1 = 37 lmin (2 s delay)

0 Adjustable

d90 Status of the eBUS roomthermostat

Current value ndash off = Not connected

on = Connected

ndash Notadjustable

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 34: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

34 Installation and maintenance instructions ENERGY 0020177746_03

Dia-gnosticscode

ParameterValues

Unit Increment select explanationDefault set-ting

Own settingMin Max

d91 Status DCF77 Current value ndash ndash ndash Notadjustable

d93 Setting the product code 0 99 ndash 1

The Device Specific Number(DSN) can be found on the iden-tification plate

ndash Adjustable

d94 Delete fault list 0 1 ndash off = No

on = Yes

ndash Adjustable

d95 Software versions ndash ndash ndash 1 = Main PCB

2 = Interface PCB

ndash Adjustable

d96 Default setting (reset) ndash ndash ndash 0 = No

1 = Yes

ndash Adjustable

C Status codes ndash Overview

Note

Since the code table is used for various products some codes may not be visible for the product in question

Status code Meaning

Displays in heating mode

S0 Heating mode No requirement

S01 Heating mode Advance fan operation

S02 Heating mode Pump pre-run

S03 Heating mode Burner ignition

S04 Heating mode Burner on

S05 Heating mode Pumpfan overrun

S06 Heating mode Fan overrun

S07 Heating mode Pump overrun

S08 Heating mode Temporary shutdown after heating procedure

Displays in hot water handling mode

S10 Hot water handling mode Requirement

S11 Hot water handling mode Advance fan operation

S13 Hot water handling mode Burner ignition

S14 DHW mode Burner on

S15 DHW mode Pumpfan overrun

S16 DHW mode Fan overrun

S17 DHW mode Pump overrun

Display in Comfort mode with warm start or hot water handling mode with cylinder

S20 Hot water handling mode Requirement

S21 Hot water handling mode Advance fan operation

S22 Hot water handling mode Pump pre-run

S23 Hot water handling mode Burner ignition

S24 DHW mode Burner on

S25 DHW mode Pumpfan overrun

S26 DHW mode Fan overrun

S27 DHW mode Pump overrun

S28 Hot water handling mode Temporary shutdown of the burner

Other displays

S30 Room thermostat is blocking heating mode

S31 No heating demand Summer mode eBUS controller waiting period

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 35: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 35

Status code Meaning

S32 Fan waiting time Fan speed outside of the tolerance values

S33 Forced fan operation until the pressure monitor is switched

S34 Frost protection active

S39 Underfloor heating contact open

S41 Water pressure too high

S42 Flue non-return flap closed

S46 Frost protection mode (Comfort) Minimum load

S53 Product in waiting periodoperation block function due to low water pressure (flowreturn spread too large)

S54 Waiting period Low water pressure in the circuit (flowreturn spread too large)

S76 Maintenance message Check the water pressure

S88 Product purging active

S91 Maintenance Demo mode

S96 Automatic test programme Return temperature sensor heating demands blocked

S97 Automatic test programme Water pressure sensor heating demands blocked

S98 Automatic test programme Return temperature sensor heating demands blocked

S99 Internal automatic test programmes

S108 Purging the combustion chamber fan in operation

S109 Products standby mode activated

D Overview of fault codes

Note

Since the code table is used for various products some codes may not be visible for the product in question

Fault code Meaning Possible cause

F00 Fault Flow temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F01 Fault Return temperature sensor NTC plug not plugged in or has come loose multiple plug on the PCB notplugged in correctly interruption in cable harness NTC sensor defective

F10 Short circuit Flow temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F11 Short circuit Return temperature sensor NTC sensor defective short circuit in the cable harness cablecasing

F12 andF91

Short circuit Cylinder temperaturesensor

NTC sensor defective short circuit in the cable harness cablecasing

F13 Short circuit Domestic hot water cylindertemperature sensor

NTC sensor defective short circuit in the cable harness cablecasing

F20 Safety switch-off Overheating temperat-ure reached

Incorrect earth connection between cable harness and product flow or returnNTC defective (loose connection) stray spark via ignition cable ignition plugor ignition electrode

F22 Safety switch-off Low water pressure inthe boiler

No or insufficient water in the product water pressure sensor de-fective cable to the pump or to the water pressure sensor loosenotconnecteddefective

F23 Safety switch-off Temperature differencetoo great (NTC1NTC2)

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

F24 Safety switch-off Temperature rise toofast

Pump blocked insufficient pump output air in product system pressure toolow non-return valve blockedincorrectly installed

F25 Safety switch-off Flue gas temperaturetoo high

Break in plug connection for optional flue gas safety cut-out (STB) break incable harness

F27 Safety switch-off Fault in flame detection Moisture on the electronics electronics (flame monitor) defective gas solen-oid valve leaking

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 36: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

36 Installation and maintenance instructions ENERGY 0020177746_03

Fault code Meaning Possible cause

F28 Fault Ignition unsuccessful when startingup

Gas meter defective or gas pressure monitor has triggered air in gas gasflow pressure too low thermal isolator device (TAE) has triggered incorrectgas restrictor incorrect spare gas valve fault on the gas valve multiple plugon PCB incorrectly plugged in break in cable harness ignition system (ig-nition transformer ignition cable ignition plug ignition electrode) defectiveionisation current interrupted (cable electrode) incorrect earthing of productelectronics defective

F29 Fault Flame loss Gas supply temporarily stopped flue gas recirculation incorrect earthing ofproduct ignition transformer has spark failure

F32 Fan frost protection function active Fanspeed outside the tolerance values

Plug on fan not correctly plugged in multiple plug on PCB not correctlyplugged in break in cable harness fan blocked Hall sensor defective elec-tronics defective

F49 eBUS fault Voltage too low Short circuit on eBUS eBUS overload or two power supplies with differentpolarities on the eBUS

F61 Fault Gas valve control system Short circuitshort to earth in cable harness for the gas valve gas valvedefective (coils shorted to earth) electronics defective

F62 Fault Gas valve switch-off control Delayed switch-off of gas valve delayed extinguishing of flame signal gasvalve leaking electronics defective

F63 Fault EEPROM Electronics defective

F64 Fault Electronicssensoranalogue-to-digital converter

Flow or return NTC short circuited electronics defective

F65 Fault Electronics temperature too high Electronics overheating due to external influences electronics defective

F67 Value sent back by ASIC is incorrect(flame signal)

Implausible flame signal electronics defective

F68 Fault Unstable flame (analogue input) Air in gas gas flow pressure too low incorrect air ratio incorrect gas re-strictor ionisation flow interruption (cable electrode)

F70 Invalid product code (DSN) Display and PCB replaced at same time and Device Specific Number notreset wrong or missing output range coding resistance

F71 Fault Flowreturn temperature sensor Flow temperature sensor signalling constant value Flow temperature sensorincorrectly positioned on supply pipe flow temperature sensor defective

F72 Fault Deviation in the water pressuresensorreturn temperature sensor

Flowreturn NTC temperature difference too great rarr flow andor return tem-perature sensor defective

F73 Fault Water pressure sensor not con-nected or has short-circuited

Interruptionshort circuit of water pressure sensor interruptionshort circuitto GND in supply line to water pressure sensor or water pressure sensordefective

F74 Fault Electrical problem in the waterpressure sensor

Line to water pressure sensor has a short circuit to 5 V24 V or internal faultin the water pressure sensor

F75 Fault Pressure sensor Pressure switch defective

F76 The safety cut-out in the primary heatexchanger is defective

Safety cut-out feedback does not match the gas valve feedback

F77 Fault Condensate or smoke No response flue non-return flap defective

F78 Interruption to DHW outlet sensor atexternal controller

UK link box is connected but hot water NTC not bridged

F83 Fault Dry fire When the burner starts the temperature change registered at the flow orreturn temperature sensor is non-existent or too small Insufficient waterin the product the flow or return temperature sensor is not in the correctposition on the pipe

F84 Fault Flowreturn temperature sensor Values not consistent difference lt -6 K

Flow and return temperature sensors signalling implausible values Flow andreturn temperature sensors have been inverted flow and return temperaturesensors have not been correctly installed

F85 Fault Temperature sensor The flow andor return temperature sensors have been installed on the samepipeincorrect pipe

Temperature sensor not connected or is connected incorrectly

F86 Fault Underfloor heating contact Underfloor heating contact open sensor disconnected or defective

F87 Fault Electrodes Electrodes not connected or they are connected incorrectly short circuit inthe cable harness

F88 Fault Gas valve Gas valve not connected or it is connected incorrectly short circuit in thecable harness

F89 Fault Pump Pump not connected or it is connected incorrectly incorrect pump connec-ted short circuit in the cable harness

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 37: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 37

Fault code Meaning Possible cause

Connection No communication between the PCBand the user interface

Electronics defective

E Wiring diagram Combi boiler

X2

X14

X21

LN

191020

263

1113

14

187

178

X51

X51

X20

16

19

3154

5

1011

6

13

X51 X35

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X1LN

RT 230Vac

X35

41

32

eBUS

RT 24V

Burner off

X106

13

41

3

31

2

M

1346

123

M

5421

21

21

N

L

L

24V230V~

24V

230V

~2

7

8

9

10

12

11

1

4

3

5

6

14

13

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 38: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

38 Installation and maintenance instructions ENERGY 0020177746_03

F Wiring diagram Combi boiler (35 kW)

X20

X40 X51

X30

X2

X21

X41

X22

X14L

N

ndash +24V=RT BUS

Burneroff

RT230Vac

X1

FUS

X106X32

X90

X12

X35

X2

X14LN

191020

263

1113

14

187

178

X12LN

X51

X51

X20

16

19

3154

5

1011

6

13

X51

X1

X21

LN

RT 230Vac

43

1

2

eBUS

RT 24V

Burner off

X106

X35 13

41

3

31

2

M

1346

123

M

4321

5421

5678

21

21

N

L

L

X35

24V230V~

24V

230V

~

2

7

8

9

10

12

11

1

4

5

6

14

13

3

1 Main PCB

2 Interface PCB

3 Timer

4 Temperature sensor on the heating flow

5 Temperature sensor on the heating return

6 Fan

7 Gas valve assembly

8 3-port diverter valve

9 Pressure sensor

10 Flow rate sensor

11 External ignition transformer

12 Heating pump

13 Ionisation and ignition electrode

14 Main power supply and connection for 230 V control

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 39: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 39

G Inspection and maintenance work ndash Overview

The table below lists the manufacturer requirements with respect to minimum inspection and maintenance intervals If na-tional regulations and directives require shorter inspection and maintenance intervals you should observe these instead ofthe intervals listed in the table

No WorkInspection(annual)

Mainten-ance

(must becarried outat regularintervals)

1Check the airflue pipe for leak-tightness and to ensure that it is fastened correctly Make surethat it is not blocked or damaged and has been installed in accordance with the relevant Installa-tion Manual

X X

2Check the general condition of the product Remove dirt from the product and from the vacuumchamber

X X

3Visually inspect the general condition of the heat exchanger In doing so pay particular attentionto signs of corrosion rust and other defects If you notice any damage carry out maintenancework

X X

4Check the gas connection pressure at maximum heat input If the gas connection pressure is notwithin the correct range carry out maintenance work

X X

5Check the CO₂ content (the air ratio) of the product and if necessary adjust it Keep a record ofthis

X X

6Disconnect the product from the power mains Check that the electrical plug connections andother connections are seated correctly and correct these if necessary

X X

7 Close the gas isolator cock and the service valves X X

8Drain the product on the water side Check the admission pressure of the expansion vessel andtop the vessel up if necessary (approx 003 MPa03 bar below the system filling pressure)

X

9 Remove the gas-air mixture unit X

10Check the seals in the combustion area If you see any damage replace the seals Replace bothburner seals each time it is opened and accordingly each time maintenance work is carried out

X

11 Clean the heat exchanger X

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

13 Check the condensate siphon in the product clean and fill if necessary X X

14 Install the gas-air mixture unit Caution Replace the seals X

15If the volume of water is insufficient or the outlet temperature is not reached replace the second-ary heat exchanger if necessary

X

16Clean the filter in the cold water inlet Replace the filter if impurities can no longer be removedor if the filter is damaged In this case also check the impeller sensor for dirt and damage cleanthe sensor (do not use compressed air for this) and replace the sensor if it is damaged

X

17 Open the gas isolator cock reconnect the product to the power mains and switch the product on X X

18Open the service valves fill up the productheating installation to 005-03 MPa05-30 bar (de-pending on the static height of the heating installation) and start purging programme PXX

X

19Perform a test operation of the product and heating installation including hot water generationand purge the system once more if necessary

X X

20 Visually inspect the ignition and burner behaviour X X

21 Check the CO₂ content (the air ratio) of the product again X

22 Check the product for gas flue gas hot water and condensate leaks and repair if necessary X X

23 Record the inspectionmaintenance work carried out X X

Note For those appliances which are not part of an annual service agreementpolicy maintenance must be carried out at least every5 years

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 40: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

40 Installation and maintenance instructions ENERGY 0020177746_03

H Position of the opening in the airflue pipe

GN

N

MM

A

II

O

H

H

CBLJ

Q Q

Q

Q

Q

K

P

D EF

I

S

R

T

H1 Positioning of the opening of a fan-supported flue gas pipe

Installation siteMinimum dimen-sions

A Directly below an opening air bricks opening windows etc that can be opened 300 mm

B Above an opening air bricks opening windows etc that can be opened 300 mm

C Horizontally to an opening air bricks opening windows etc that can be opened 300 mm

DBelow temperature-sensitive building components eg plastic gutters down pipes or wastewaterpipes

75 mm

E Below eaves 200 mm

F Below balconies or car port roofs 200 mm

G From vertical wastewater pipes or down pipes 150 mm

H From external or internal corners 200 mm

I Above floors roofs or balconies 300 mm

J From a surface facing a terminal 600 mm

K From a terminal facing a terminal 1200 mm

L From an opening in the car port (eg door window) which leads into the dwelling 1200 mm

M Vertical from a terminal on the same wall 1500 mm

N Horizontal from a terminal on the same wall 300 mm

O From the wall on which the terminal has been installed 0 mm

P From a vertical structure on the roof 300 mm

Q Above the roof area 300 mm

R Horizontal from adjacent windows on pitched or flat roofs 600 mm

S Above adjacent windows on pitched or flat roofs 600 mm

T Below adjacent windows on pitched or flat roofs 2000 mm

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 41: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 41

H2 Horizontal terminal positioning

BS 5440-1 recommends that fanned flue chimney terminals should be positioned as follows

a) at least 2 m from an opening in the building directly opposite and

b) so that the products of combustion are not directed to discharge directly across a boundary if the products are likely tocause a nuisance to a neighbour or discharge over a walkway or patio

For IE see current issue of IS 813

For boilers covered within this manual

1) 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 con-densate plume does not affect adjacent surfaces the terminal should be extended as shown below

Balconyeaves

Gutter

Adequately secured airflue gas pipe

The flue pipe mustprotrude beyond any overhang

2) Dimension H

This clearance may be reduced to 25 mm without affecting the performance of the boiler However in order to ensure thatthe condensate plume does not affect adjacent surfaces a clearance of 300 mm is preferred

For 1 and 2 above you can use a flue gas management kit to enable the termination point to be positioned and directed awayfrom the building fabric

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 42: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

42 Installation and maintenance instructions ENERGY 0020177746_03

I Commissioning Checklist

copy Heating and Hotwater Industry Council (HHIC)

wwwcentralheatingcouk

Benchmark Commissioning and Servicing SectionIt is a requirement that the boiler is installed and commissioned to the

completed in full

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 43: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 43

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

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

CONTROLS

Optimum start control

Fitted

Fitted

Fitted

Fitted

ALL SYSTEMS

Yes

Yes

CENTRAL HEATING MODE

OR

mbar OR mbar

COMBINATION BOILERS ONLY

Yes

Yes

DOMESTIC HOT WATER MODE

OR

mbar OR mbar

Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS

AND sup2 Ratio

AND sup2 Ratio

Yes

Yes

Yes

Yes

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 44: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

44 Installation and maintenance instructions ENERGY 0020177746_03

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

Service Provider

SERVICE RECORD

SERVICE 01

AND sup2 AND sup2

SERVICE 02

AND sup2 AND sup2

SERVICE 03

AND sup2 AND sup2

SERVICE 04

AND sup2 AND sup2

SERVICE 05

AND sup2 AND sup2

SERVICE 06

AND sup2 AND sup2

SERVICE 07

AND sup2 AND sup2

SERVICE 08

AND sup2 AND sup2

SERVICE 09

AND sup2 AND sup2

SERVICE 10

AND sup2 AND sup2

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 45: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 45

PRIOR TO CO AND COMBUSTION RATIO CHECKThe boiler manufacturerrsquos installation instructions should have been followed gas type verified and gas

supply pressurerate checked as required prior to commissioningAs 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 manufacturerrsquos max flue lengths have not been

exceeded and all guidance has been followed (eg 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 manufacturerrsquos instructions

NOTETHE 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

installerservice engineer must be competent to carry out this work and to use the flue gas

analyser accordinglyIf the boiler requires conversion to operate with

a different gas family (eg conversion from natural gas to LPG) separate guidance will be

provided by the boiler manufacturer

CARRY OUT FLUE INTEGRITY CHECK USING ANALYSERInsert analyser probe into air inlet test point and allow readings to stabiliseNOTE - 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 ldquoPrior to

CO and combustion ratio checkrdquo box above before proceeding to the ldquoCheck CO and combustion ratio at maximum raterdquo stage below

SET BOILER TO MINIMUM RATEIn accordance with boiler instructions set boiler to operate at minimum rate (to

minimum load condition) Allow sufficient time for combustion to stabiliseNOTE - If manufacturerrsquos instructions do not specify how to set boiler to minimum

rate contact Technical Helpline for advice

CHECK CO AND COMBUSTION RATIO AT MINIMUM RATEWith boiler still set at minimum rate insert analyser probe into flue gas sampling

point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is not

specified in the manual consult boiler manufacturer for guidance

CHECK CO AND COMBUSTION RATIO AT MAX RATEWith boiler still set at maximum rate insert analyser probe into flue gas

sampling point Allow readings to stabilise before recordingNOTE - If no flue gas sampling point is present and the correct procedure is

not specified in the manual consult boiler manufacturer for guidance

SET BOILER TO MAXIMUM RATEIn accordance with boiler instructions set boiler to operate at max rate

(full load condition) Allow sufficient time for combustion to stabiliseNOTE - Do not insert analyser probe during this period to avoid

possible ldquofloodingrdquo of sensor

IsCO less than 350ppm andCOCO2 ratio

less than 0004

IsO2 206

andCO2 lt 02

IsCO less than 350ppm andCOCO2 ratio

less than 0004

BOILER IS OPERATING SATISFACTORILYno 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

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE APPLIANCE MUST NOT BE

COMMISSIONED UNTIL PROBLEMS ARE IDENTIFIED AND RESOLVED

VERIFY FLUE INTEGRITYAnalyser readings indicate that combustion products and inlet air must be mixing Further investigation of

the flue is therefore requiredCheck that flue components are assembled fixed and supported as per boilerflue manufacturerrsquos

instructionsCheck that flue and flue terminal are not obstructed

IsCO less than

335ppmand

COCO2 ratio less than 0004

IsO2 206

andCO2 lt 02

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

Rectify where necessary

TURN OFF APPLIANCE AND CALL MANUFACTURERrsquoS TECHNICAL HELPLINE

FOR ADVICETHE 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

NO

NO

NO

NO

YES

YES

YESYES

YES

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 46: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

46 Installation and maintenance instructions ENERGY 0020177746_03

J Pipe lengths for the airflue pipe

J1 Length of the C13 type airflue pipe

Applicability C13 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C13 type airfluepipe

C13 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J2 Length of the C33 type airflue pipe

Applicability C33 type airflue pipe

Diameter of the airflue pipe

Dia 60100 (L) Dia 80125 (L)

C33 type airfluepipe

C33 type airfluepipe

ENERGY 25c -A(H-GB)

le 10 m le 25 m

ENERGY 30c -A(H-GB)

le 10 m le 25 m

ENERGY 35c -A(H-GB)

le 10 m le 25 m

J3 Length of the C43 type airflue pipe

Applicability C43 type airflue pipe

Diameter of theairflue pipe

Dia 60100 (L)

C43 type airfluepipe

ENERGY 25c -A(H-GB)

le 5 m

ENERGY 30c -A(H-GB)

le 5 m

ENERGY 35c -A(H-GB)

le 5 m

K Technical data

Technical data ndash Heating

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Max flow temperature adjustmentrange (default setting 75 degC)

10 hellip 80 10 hellip 80 10 hellip 80

Maximum permissible pressure 03 MPa

(30 bar)

03 MPa

(30 bar)

03 MPa

(30 bar)

Nominal water flow (ΔT = 20 K) 788 lh 1094 lh 1102 lh

Nominal water flow (ΔT = 30 K) 525 lh 729 lh 876 lh

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 47: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

0020177746_03 ENERGY Installation and maintenance instructions 47

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Approximate value for thecondensate volume (pH valuebetween 35 and 40) at 5030 degC

184 lh 255 lh 257 lh

ΔP heating at nominal flow (ΔT =20 K)

0025 MPa

(0250 bar)

0025 MPa

(0250 bar)

0018 MPa

(0180 bar)

Technical data ndash G20 powerloading G20The lowest nominal heat output may be higher than the value in the technical data depending on the design of the systemand the current operating status

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Maximum heat output 18 kW 25 kW 25 kW

Effective output range (P)at 4030 degC

54 hellip 195 kW 65 hellip 270 kW 76 hellip 272 kW

Effective output range (P)at 5030 degC

53 hellip 191 kW 63 hellip 265 kW 75 hellip 267 kW

Effective output range (P)at 8060 degC

50 hellip 183 kW 61 hellip 254 kW 72 hellip 256 kW

Domestic hot water heatoutput (P)

50 hellip 252 kW 60 hellip 300 kW 71 hellip 350 kW

Maximum heat input ndashheating (Q max)

184 kW 255 kW 257 kW

Minimum heat input ndash heat-ing (Q min)

51 kW 61 kW 72 kW

Maximum heat input ndash hotwater (Q max)

257 kW 306 kW 357 kW

Minimum heat input ndash hotwater (Q min)

51 kW 61 kW 72 kW

Technical data ndash Domestic hot water

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Specific flow rate (D) (ΔT = 30 K)in accordance with EN 13203

121 lmin 142 lmin 165 lmin

Continuous flow rate (ΔT = 35 K) 622 lh 730 lh 849 lh

Specific flow rate (ΔT = 35 K) 104 lmin 122 lmin 141 lmin

Minimum permissible pressure 003 MPa

(030 bar)

003 MPa

(030 bar)

003 MPa

(030 bar)

Maximum permissible pressure 1 MPa

(10 bar)

1 MPa

(10 bar)

1 MPa

(10 bar)

Recommended pressure 02 MPa

(20 bar)

02 MPa

(20 bar)

02 MPa

(20 bar)

Temperature range 35 hellip 60 35 hellip 60 35 hellip 60

Flow rate limiter 80 lmin 100 lmin 120 lmin

Technical data ndash General

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas category I2H I2H I2H

Diameter of the gas pipe 12 inch 12 inch 12 inch

Diameter of the heating connec-tions

34 inch 34 inch 34 inch

Expansion relief valve connector(min)

15 mm 15 mm 15 mm

Condensate drain pipework (min) 215 mm 215 mm 215 mm

G20 gas supply pressure 20 kPa

(200 mbar)

20 kPa

(200 mbar)

20 kPa

(200 mbar)

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 48: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Appendix

48 Installation and maintenance instructions ENERGY 0020177746_03

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Gas flow at P max ndash hot water(G20)

27 msup3h 32 msup3h 38 msup3h

Gas flow at P max ndash heating mode(G20)

19 msup3h 27 msup3h 27 msup3h

Gas flow at P min (G20) 0540 msup3h 0646 msup3h 0762 msup3h

CE number (PIN) CE-0063CP3646 CE-0063CP3646 CE-0063CP3646

Flue gas mass rate in heatingmode at P min

234 gs 280 gs 330 gs

Flue gas mass rate in heatingmode at P max

83 gs 115 gs 116 gs

Flue gas mass rate in hot waterhandling mode at P max

116 gs 138 gs 161 gs

Flue gas temperature (80 degC60 degC)at P max

60 77 82

Flue gas temperature (80 degC60 degC)at P min

55 55 56

Flue gas temperature (50 degC30 degC)at P max

51 62 56

Flue gas temperature (50 degC30 degC)at P min

34 35 37

Flue gas temperature in hot waterhandling mode

69 68 75

Flue gas temperature when over-heating

105 95 104

Released system types C13 C33 C43 C13 C33 C43 C13 C33 C43

Nominal efficiency at 8060 degC 996 996 996

Nominal efficiency at 5030 degC 1040 1040 1040

Nominal efficiency at 4030 degC 1060 1060 1060

Nominal efficiency in partial loadoperation (30) at 4030 degC

1085 1085 1085

NOx class 5 5 5

Product dimensions width 390 mm 390 mm 390 mm

Product dimensions depth 280 mm 280 mm 280 mm

Product dimensions height 700 mm 700 mm 700 mm

Net weight 32 kg 33 kg 33 kg

Weight when filled with water 36 kg 38 kg 38 kg

Technical data ndash Electrics

ENERGY 25c -A (H-GB)

ENERGY 30c -A (H-GB)

ENERGY 35c -A (H-GB)

Electric connection 230 V 50 Hz 230 V 50 Hz 230 V 50 Hz

Built-in fuse (slow-blow) T22A 250V T22A 250V T22A 250V

Max electrical power consump-tion

66 W 75 W 60 W

Standby electrical power con-sumption

2 W 2 W 3 W

Level of protection IPX4D IPX4D IPX4D

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 49: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

Index

0020177746_03 ENERGY Installation and maintenance instructions 49

Index

AAirflue pipe installed 5BBurner anti-cycling time 21Bypass valve 22CCE label 8Check programmes 30

Using 16Checking the burner 25Checking the pre-charge pressure of the expansionvessel 26Cleaning the condensate siphon 25Cleaning the heat exchanger 24CO₂ content

Checking 20 23Competent person 4Completing inspection work 26Completing maintenance work 26Condensate discharge pipe 12Condensate siphon

Filling 18Controller 15Corrosion 5DDecommissioning 29Decommissioning the product 29Diagnostics codes

Using 15Documents 7Draining the product 26EElectricity 5Expansion relief valve 28FFault codes 26Fault memory 26Fault messages 26Fault symbol 16Flow rate-pressure curves 21Flue gas route 5Front casing closed 5Frost 5GGas family check 16Gas flow rate 18HHanding over to the end user 22High-efficiency pump 21High-efficiency pump output 21IIdentification plate 7If you smell flue gas 5If you smell gas 4Inspection work 22 39Installation site 5Intended use 4LLeak-tightness 20 26 29

MMaintenance work 22 39Minimum clearance 9PPower supply 14Preparing the repair work 26Preparing repair work 26Pressure sensor 29Pump head 27QQualification 4RRegulations 6Removing the air intake pipe 24Removing the burner 24Removing the flue gas pipe 24Removing the front casing 10Removing the gas-air mixture unit 24Removing the ignition transformer 24Removing the side section 10Replacing the burner 26Replacing the expansion vessel 28Replacing the heat exchanger 26Replacing the main PCB 28Replacing the PCB for the user interface 28Replacing expansion vessel 28Resetting the burner anti-cycling time 21SSafety device 5Schematic drawing 5Setting the burner anti-cycling time 21Spare parts 23Switching on the product 18TTool 6Transport 5Transporting 8Treating the heating water 16UUnloading the box 8Unpacking the product 8Using

Check programmes 16Diagnostics codes 15

VVoltage 5Volume flow sensor 29WWall-mounting the product 9Weight 9

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W
Page 50: Installationandmain- tenanceinstructions - …...4Set-up 8 InstallationandmaintenanceinstructionsENERGY0020177746_03 Informationonthe identificationplate Meaning Readtheinstructions

0020177746_03

ManufacturerSupplierVaillant Group UK LTD

Nottingham Road ‒ Belper ‒ Derbyshire DE56 1JQ

Telephone 01773 824639 ‒ Technical helpline 0330 100 7679

After sales service 0330 100 3142

wwwglow-wormcouk

0020177746_03 ‒ 16112017

copy These instructions or parts thereof are protected by copyright and may be repro-duced or distributed only with the manufacturers written consent

We reserve the right to make technical changes

  • Contents
  • 1 Safety
    • 11 Action-related warnings
    • 12 Risk caused by inadequate qualifications
    • 13 Intended use
    • 14 General safety information
      • 141 Risk of death from escaping gas
      • 142 Risk of death from escaping flue gas
      • 143 Risk of death due to blocked or leaking flue gas routes
      • 144 Risk of death due to explosive and flammable materials
      • 145 Risk of death from electric shock
      • 146 Risk of death due to lack of safety devices
      • 147 Risk of poisoning and burns caused by escaping hot flue gases
      • 148 Risk of being burned or scalded by hot components
      • 149 Risk of injury due to the heavy weight of the product
      • 1410 Risk of corrosion damage due to unsuitable combustion and room air
      • 1411 Risk of material damage caused by frost
      • 1412 Risk of material damage caused by using an unsuitable tool
        • 15 Regulations (directives laws standards)
          • 2 Notes on the documentation
            • 21 Observing other applicable documents
            • 22 Storing documents
            • 23 Validity of the instructions
            • 24 Benchmark
              • 3 Product description
                • 31 Compartment Ventilation
                • 32 Information on the identification plate
                • 33 Functional elements Combination unit
                • 34 CE label
                  • 4 Set-up
                    • 41 Transporting the unit
                      • 411 General
                      • 412 Unloading the box from the delivery van
                        • 42 Unpacking the product
                        • 43 Checking the scope of delivery
                        • 44 Dimensions
                        • 45 Minimum clearances
                        • 46 Using the mounting template
                        • 47 Wall-mounting the product
                        • 48 Removinginstalling the front casing
                          • 481 Removing the front casing
                          • 482 Installing the front casing
                            • 49 Removinginstalling the side section
                              • 491 Removing the side section
                              • 492 Installing the side section
                                  • 5 Installation
                                    • 51 Checking the gas meter
                                    • 52 Gas and water connections
                                    • 53 Connecting the drain pipework for the expansion relief valve
                                    • 54 Connecting the condensate discharge pipe
                                      • 541 Condensate drainage systems
                                        • 5411 Internal soil and vent pipe
                                        • 5412 External soil and vent pipe
                                        • 5413 External termination into a gulley or hopper
                                        • 5414 Internal termination into combined sink waste
                                        • 5415 Internal termination downstream of sink waste
                                        • 5416 External termination into soakaway
                                        • 5417 External termination into rain water down pipe
                                            • 55 Electrical installation
                                              • 551 Opening the electronics box
                                              • 552 Closing the electronics box
                                              • 553 Cable route
                                              • 554 Carrying out the wiring
                                              • 555 Establishing the power supply
                                              • 556 Connecting controllers to the electronic system
                                                  • 6 Operation
                                                    • 61 Using diagnostics codes
                                                      • 611 Activating diagnostics codes
                                                      • 612 Setting a diagnostics code
                                                        • 62 Displaying the status codes
                                                          • 621 Activating the status codes display
                                                            • 63 Using check programmes
                                                              • 631 Calling up the check programmes
                                                              • 632 Displaying the pressure and temperature of the heating during a check programme
                                                                  • 7 Start-up
                                                                    • 71 Carrying out the initial start-up
                                                                    • 72 Checking the type of gas
                                                                    • 73 Checking the factory setting
                                                                    • 74 Checking and treating the heating waterfilling and supplementary water
                                                                    • 75 Avoiding danger arising from insufficient water pressure
                                                                    • 76 Switching on the product
                                                                    • 77 Filling and purging the heating installation
                                                                    • 78 Filling the condensate siphon
                                                                    • 79 Filling the hot water circuit
                                                                    • 710 Checking and adjusting the gas settings
                                                                      • 7101 Checking the gas flow rate
                                                                      • 7102 Checking the gas connection pressure (gas flow pressure)
                                                                      • 7103 Checking the leak-tightness of the flue gas installation and flue gas recirculation
                                                                      • 7104 Thoroughly flushing the heating installation (hot)
                                                                      • 7105 Checking the CO₂ content
                                                                        • 711 Checking leak-tightness
                                                                          • 7111 Checking the heating mode
                                                                          • 7112 Checking the hot water generation
                                                                              • 8 Adapting the unit to the heating installation
                                                                                • 81 Burner anti-cycling time
                                                                                  • 811 Setting the maximum burner anti-cycling time
                                                                                  • 812 Resetting the remaining burner anti-cycling time
                                                                                    • 82 Setting the pump output
                                                                                    • 83 Setting the bypass valve
                                                                                    • 84 Setting the hot water temperature
                                                                                      • 9 Handing the product over to the
                                                                                      • 10 Inspection and maintenance
                                                                                        • 101 Using original seals
                                                                                        • 102 Observing inspection and maintenance intervals
                                                                                        • 103 Procuring spare parts
                                                                                        • 104 Checking the CO₂ content
                                                                                        • 105 Setting the CO₂ content
                                                                                        • 106 Removing the gas-air mixture unit
                                                                                        • 107 Cleaning the heat exchanger
                                                                                        • 108 Checking the burner
                                                                                        • 109 Checking the ignition electrode
                                                                                        • 1010 Cleaning the condensate siphon
                                                                                        • 1011 Cleaning the filter in the cold water inlet
                                                                                        • 1012 Cleaning the heating filter
                                                                                        • 1013 Installing the gas-air mixture unit
                                                                                        • 1014 Draining the product
                                                                                        • 1015 Checking the admission pressure of the expansion vessel
                                                                                        • 1016 Completing inspection and maintenance work
                                                                                        • 1017 Checking the product for leak-tightness
                                                                                          • 11 Troubleshooting
                                                                                            • 111 Rectifying faults
                                                                                            • 112 Calling up the fault memory
                                                                                            • 113 Deleting the fault memory
                                                                                            • 114 Resetting parameters to factory settings
                                                                                            • 115 Preparing the repair work
                                                                                            • 116 Replacing defective components
                                                                                              • 1161 Replacing the burner
                                                                                              • 1162 Replacing the gas-air mixture unit
                                                                                              • 1163 Replacing the heat exchanger
                                                                                              • 1164 Replacing the pump head
                                                                                              • 1165 Replacing the expansion vessel
                                                                                              • 1166 Replacing the main PCB
                                                                                              • 1167 Replacing the PCB for the user interface
                                                                                              • 1168 Replacing the expansion relief valve
                                                                                              • 1169 Replacing the volume flow sensor
                                                                                              • 11610 Replace the pressure sensor
                                                                                                • 117 Checking the product for leak-tightness
                                                                                                  • 12 Decommissioning the product
                                                                                                  • 13 Customer service
                                                                                                  • Appendix
                                                                                                    • A Check programmes ndash Overview
                                                                                                    • B Overview of diagnostics codes
                                                                                                    • C Status codes ndash Overview
                                                                                                    • D Overview of fault codes
                                                                                                    • E Wiring diagram Combi boiler
                                                                                                    • F Wiring diagram Combi boiler (35 kW)
                                                                                                    • G Inspection and maintenance work ndash Overview
                                                                                                    • H Position of the opening in the airflue pipe
                                                                                                      • H1 Positioning of the opening of a fan-supported flue gas pipe
                                                                                                      • H2 Horizontal terminal positioning
                                                                                                        • I Commissioning Checklist
                                                                                                        • J Pipe lengths for the airflue pipe
                                                                                                          • J1 Length of the C13 type airflue pipe
                                                                                                          • J2 Length of the C33 type airflue pipe
                                                                                                          • J3 Length of the C43 type airflue pipe
                                                                                                            • K Technical data
                                                                                                              • Index
                                                                                                                • A
                                                                                                                • B
                                                                                                                • C
                                                                                                                • D
                                                                                                                • E
                                                                                                                • F
                                                                                                                • G
                                                                                                                • H
                                                                                                                • I
                                                                                                                • L
                                                                                                                • M
                                                                                                                • P
                                                                                                                • Q
                                                                                                                • R
                                                                                                                • S
                                                                                                                • T
                                                                                                                • U
                                                                                                                • V
                                                                                                                • W