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- WarmFlow
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- GC29B
- Manual
WarmFlow GC29B Manual
Summary of GC29B
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Tr05a140.B1107 boiler manual incorporating: user instructions installation instructions commissioning instructions maintenance instructions commissioning certificate service record high efficiency condensing gas boilers model covered by this manual: g-series gs25a gas premix system boiler sedbuk.
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Tr05a140.B1107.
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Contents tr05a140.B1107 1 user instructions 3 1.1 boiler controls 3 1.1.1 control panel layout 3 1.1.2 operating the appliance 3 1.2 topping up the system (error code h20) 4 1.3 if you smell gas 4 2 general information 5 2.1 general warnings 5 2.2 information 5 2.3 product conformity 7 3 technical c...
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Contents tr05a140.B1107 5.7 control parameter adjustment 36 5.7.1 accessing the parameters menu 36 5.7.2 adjusting the parameters 37 5.8 gas data 42 5.8.1 technical reference tables 42 6 maintenance 43 6.1 general warnings 43 6.2 boiler inspection 43 6.3 accessing the boiler 44 6.3.1 front panel rem...
Page 5: 1 User Instructions
General information tr05a140.B1107 3 1 user instructions 1.1 boiler controls 1.1.1 control panel layout 1. On/off button 2. Central heating control knob 3. Button 4. S button 5. Button 6. Mains supply terminal board 7. Digital lcd display 8. Programmer location (n/a) 1.1.2 operating the appliance op...
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General information tr05a140.B1107 4 1.2 topping up the system (error code h20) if the water pressure in the central heating circuit falls below 0.3 bar, the boiler will go to lock out (stop working) and error code h2o will appear on the display. This could be caused be a leak in the system, if air ...
Page 7: 2 General Information
General information tr05a140.B1107 5 2 general information 2.1 general warnings this appliance must only be installed and commissioned by professionally qualified personnel in accordance with current laws and standards and in line with the manufacturer’s instructions. In the united kingdom, the inst...
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General information tr05a140.B1107 6 • when the appliance is no longer required for use, any parts that may constitute potential sources of danger must be rendered harmless. • only original accessories or optional extras (including electrical parts) may be used with the appliance. • should there be ...
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General information tr05a140.B1107 7 2.3 product conformity warmflow declares that all its products are manufactured to a high specification and in compliance with the relevant standards. All warmflow gas boilers are ce certified and possess technical and functional characteristics that comply with ...
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Technical characteristcs tr05a140.B1107 8 3 technical characteristics 3.1 technical data model gs25a appliance type c13, c33, c43, c53, c63, c83 appliance category ii2h3+ heat input max kw 25 heat input min kw 9 heat output max (50/30°) kw 26.67 efficiency 100% (full load 50/30°) % 106.7 efficiency ...
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Technical characteristcs tr05a140.B1107 9 110 137 163 2 8 5 1 3 2 7 3 0 hf g hr 148 49 182 31 285 7 3 0 111.5 187 111.5 48.5 313 48.5 105 on / off 3.2 dimensions legend hr heating return 22mm hf heating flow 22mm g gas 22mm sc condensate drain 25mm figure 2: dimensions.
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Technical characteristcs tr05a140.B1107 10 3.3 internal components legend 1. Primary condensing heat exchanger 2. Premix burner unit (gas manifold + burner) 3. Heat exchanger condensate drain connection 4. Ionisation electrode 5. Ignition electrode 6. Fan 7. Venturi 8. Ignition transformer 9. Electr...
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Technical characteristcs tr05a140.B1107 11 3.4 function diagram legend 1. Primary condensing heat exchanger 2. Premix burner unit (gas manifold & burner) 3. Heat exchanger condensate drain pipe 4. Ionisation electrode 5. Ignition electrode 6. Fan 7. Venturi 8. Ignition transformer 9. Electronic gas ...
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Technical characteristcs tr05a140.B1107 12 3.5 circulation pump performance curves figure 5: pump performance curves i ii i ii iii 1400 1200 1600 70 50 60 40 1000 800 400 600 30 10 20 0 0 200 iii appliance loss available head at minimum speed available head at second speed available head at maximum ...
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Technical characteristcs tr05a140.B1107 13 3.6 control panel and display the appliance must be supplied with a permanent live in order for the boiler’s protective functions to operate. These functions include frost protection, post-ventilation, pump overrun and pump & 3-way valve inactivity protecti...
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Technical characteristcs tr05a140.B1107 14 3.6.3 function codes code function description 07 commissioning mode operates the boiler at maximum ch output for 15 minutes without modulation. Activated by pressing and holding the s button for 7 seconds. Deactivated by switching the appliance off. 08 ch ...
Page 17: 4 Installation
Installation instructions tr05a140.B1107 15 4 installation 4.1 reference standards in the united kingdom, the installation of this appliance must be carried out by a corgi registered installer. To check for authorised qualified engineers contact corgi on 0870 401 2300. The installation must be carri...
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Installation instructions tr05a140.B1107 16 4.2 unpacking ■ the materials (cardboard) used for packing the appliance are fully recyclable. ■ it is recommended that the packing material is only removed when the appliance is ready to be installed. The manufacturer will not be held responsible for dama...
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Installation instructions tr05a140.B1107 17 4.3 installing the boiler ■ the appliance must only be installed on a flat vertical solid wall capable of supporting its weight. ■ the boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.E. Garage or outhouse. ■...
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Installation instructions tr05a140.B1107 18 148 49 182 31 hr g hf 1 0 5 4.4 water connections in order to comply with the terms & conditions of warranty, the system must be hot-flushed to remove any impurities (especially oil and grease) from the pipes and radiators. The ch pipes must be adequately ...
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Installation instructions tr05a140.B1107 19 4.4.1 central heating circuit the boiler is designed for use in a sealed central heating system in accordance with the requirements of bs 5449 and bs 6798. The system should be designed to operate with flow temperatures of up to 82°c. When designing the sy...
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Installation instructions tr05a140.B1107 20 4.5 condensate drain failure to install the condensate discharge pipe work correctly will affect the reliable operation of the boiler. The condensate discharge pipe must not rise at any point along its length. There must be a fall of at least 2.5° (50mm pe...
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Installation instructions tr05a140.B1107 21 4.6 gas connection the connection to the gas supply must be carried out by professionally qualified personnel in accordance with relevant standards. When connecting the boiler to the gas supply pipe, only use appropriate washers and gas fittings. The use o...
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Installation instructions tr05a140.B1107 22 4.7 electrical connections 4.7.1 general warnings the connection to the mains power supply must be carried out by professionally qualified personnel, registered in accordance with current legislation. Always check to make sure that the appliance has an eff...
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Installation instructions tr05a140.B1107 23 4.7.2 power supply the connection to the mains power supply must be carried out by professionally qualified personnel, registered in accordance with current legislation. Connect the power supply to the terminal board inside the control panel as follows: a....
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Installation instructions tr05a140.B1107 24 4.8 flue connections in order to ensure that the appliance functions correctly and efficiently, only warmflow-approved flue components may be used with this appliance. Traditional flue components cannot be used for conveying exhaust fumes from condensing b...
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Installation instructions tr05a140.B1107 25 4.8.1 flue position the flue system must be installed in accordance with the recommendation contained in bs 5440:1. The boiler must be installed so that the terminal is exposed to the external air. It is important that the position of the terminal allows f...
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Installation instructions tr05a140.B1107 26 4.8.2 horizontal coaxial balanced flue – Ø 60/100 (kit k) figure 18: Ø 60/100 horizontal kit k figure 19: Ø 60/100 horizontal kit k dimensions for condensing boilers only Ø 60/100 maximum flue length = 5 m * the flue length is the total length of the flue ...
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Installation instructions tr05a140.B1107 27 4.8.3 horizontal coaxial balanced flue – Ø 80/125 figure 20: Ø 80/125 horizontal kit figure 21: Ø 80/125 horizontal kit dimensions for condensing boilers only Ø 80/125 maximum flue length = 7 m * the flue length is the total length of the flue excluding th...
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Installation instructions tr05a140.B1107 28 4.8.4 vertical coaxial balanced flue – Ø 60/100 (kit v) figure 22: Ø 60/100 vertical kit v figure 23: Ø 60/100 vertical kit v dimensions for condensing boilers only Ø 60/100 maximum flue length = 5 m * the flue length is the total length of the flue exclud...
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Installation instructions tr05a140.B1107 29 4.8.5 vertical coaxial balanced flue – Ø 80/125 figure 24: Ø 80/125 verical kit figure 25: Ø 80/125 verical kit dimensions for condensing boilers only Ø 80/125 maximum flue length = 7 m * the flue length is the total length of the flue excluding the first ...
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Installation instructions tr05a140.B1107 30 4.8.6 twin pipe flue system – Ø 80/80 (kit h) figure 26: Ø 80/80 twin pipe kit h figure 27: Ø 80/80 twin pipe kit h dimensions for condensing boilers only Ø 80/80 maximum flue length = 50 m the flue length is the total length of both the intake and exhaust...
Page 33: 5 Commissioning
Commissioning instructions tr05a140.B1107 31 5 commissioning 5.1 general warnings the following operations must be carried out by professionally qualified personnel, registered in accordance with current legislation. Reference should be made to bs 5449:5 - commissioning. The boiler leaves the factor...
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Commissioning instructions tr05a140.B1107 32 rs m 5.2 filling the system use only a wras approved filling loop for connection and filling of the primary system. This should be disconnected when not in use (see section 4.4.2). Check the properties of the water supply and use appropriate treatment age...
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Commissioning instructions tr05a140.B1107 33 5.3 flushing the system failure to flush and add inhibitor to the system will invalidate the warranty. The system must be thoroughly drained and flushed out using flushing agents/descalers that comply with bs7593. When refilling the system, appropriate co...
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Commissioning instructions tr05a140.B1107 34 5.5 starting the boiler once the system has been flushed and filled, proceed as follows: • check that the exhaust flue is free of obstructions and correctly connected to the boiler; • check that all isolation valve are open (ch circuit and gas) • switch o...
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Commissioning instructions tr05a140.B1107 35 5.6 control parameters table 6: control parameters notes factory default values highlighted in bold. Parameters 1 and parameter 14 highlighted in grey only need to be adjusted when replacing the modulation pcb. When the pcb is replaced and parameter 14 is...
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Commissioning instructions tr05a140.B1107 36 5.7 control parameter adjustment 5.7.1 accessing the parameters menu step 1: switch the appliance off using the on/off button. Step 2: press and hold both the & buttons. Switch the appliance on using the on/off button. Release the & buttons. Step 3: press...
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Commissioning instructions tr05a140.B1107 37 5.7.2 adjusting the parameters parameter 1 – boiler type access the parameters menu as described in section 5.7.1. Use the & buttons to adjust the parameter value: 00 = non-storage boiler; 01 = storage boiler (type 1); 02 = storage boiler (type 2). Press ...
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Commissioning instructions tr05a140.B1107 38 parameter 4 – ch pump mode access the parameters menu as described in section 5.7.1. Use the & buttons to adjust the parameter value: 00 = runs when controls call for heat 01 = runs continuously when appliance is on press and release the s button. The par...
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Commissioning instructions tr05a140.B1107 39 parameters 8 through 13 not applicable to this appliance parameter 14 – burner type access the parameters menu as described in section 5.7.1. Use the & buttons to adjust the parameter value: 00 = atmospheric burner (all outputs); 01 = premix burner – 25 k...
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Commissioning instructions tr05a140.B1107 40 parameter 17 – minimum fan speed access the parameters menu as described in section 5.7.1. Use the & buttons to adjust the parameter value: 33 = 33 hz (minimum) maximum value determined by parameter 18 note: factory preset to 66 = 66 hz press and release ...
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Commissioning instructions tr05a140.B1107 41 parameter 21 – ignition sequence fan speed access the parameters menu as described in section 5.7.1. Use the & buttons to adjust the parameter value: minimum value determined by parameter 17 maximum value determined by parameter 18 note: factory preset to...
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Commissioning instructions tr05a140.B1107 42 5.8 gas data 5.8.1 technical reference tables gas type co 2 concentration / % natural gas (methane) – g20 9.4 lpg (butane) – g30 10.9 lpg (propane) – g31 11.0 table 7: reference carbon dioxide concentrations gas type minimum fan speed / hz maximum fan spe...
Page 45: 6 Maintenance
Maintenance instructions tr05a140.B1107 43 6 maintenance 6.1 general warnings all maintenance operations must be carried out by professionally qualified personnel. The frequency of boiler maintenance must comply with current law and should, in any case, be carried out annually. In order to guarantee...
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Maintenance instructions tr05a140.B1107 44 6.3 accessing the boiler all maintenance operations require one or more of the boiler casing panels to be removed. 6.3.1 front panel removal • remove the fixing screws at the lower edge of the front panel; • grasp the lower part of the panel and pull it out...
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Maintenance instructions tr05a140.B1107 45 6.4 draining the central heating system if the entire system needs to be drained: • switch on the boiler, select heating only mode and allow the boiler to fire. Refer to section 3.6 for how to operate the appliance; • isolate the electricity and gas supplie...
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Maintenance instructions tr05a140.B1107 46 6.6 maintenance operations before carrying out any cleaning or part replacement operations, always turn off the electricity, water and gas supplies to the boiler.Warmflow will not be held responsible for damage to any of the boiler’s components caused by no...
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Maintenance instructions tr05a140.B1107 47 6.6.1 primary heat exchanger and burner unit • isolate the electricity, water and gas supplies to the appliance; • disconnect the electrical connections of the electric fan; • disconnect and remove the pipe linking the gas valve to the venturi; • disconnect...
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Maintenance instructions tr05a140.B1107 48 6.6.2 ignition and ionisation electrodes • isolate the electricity, water and gas supplies to the appliance; • unplug the electrode wires; • slacken the fixing screws; • remove the electrodes. When refitting the electrodes, check that the seals are not dama...
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Maintenance instructions tr05a140.B1107 49 6.6.5 gas valve • isolate the electricity, water and gas supplies to the appliance; • disconnect and remove the gas pipe connecting the gas valve to the venturi; • disconnect the gas feed pipe and valve ring nut at the bottom of the room sealed chamber; • r...
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Maintenance instructions tr05a140.B1107 50 6.6.7 electric fan • isolate the electricity, water and gas supplies to the appliance; • remove and dismantle the entire burner unit (see section 6.6.1); • use an 8 mm spanner to unscrew the four nuts securing the electric fan to the gas manifold and then r...
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Maintenance instructions tr05a140.B1107 51 6.6.9 modulation circuit board • isolate the electricity, water and gas supplies to the appliance; • access the control panel (see section 6.3); • disconnect all the connectors, remove the control knobs from the front of the panel, unscrew the fixing screws...
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Maintenance instructions tr05a140.B1107 52 6.7 wiring diagram m7 m5 m9 m4 m6 m2 1 2 3 4 5 6 6 7 8 m1 1 2 3 4 5 6 1 2 3 4 5 6 7 1 2 3 4 1 2 3 4 5 6 5 4 m10 3 2 1 zone valve management + option remote controller board zone valve contact closure remote controller zone valve telephone control remote con...
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Maintenance instructions tr05a140.B1107 53 6.8 troubleshooting 6.8.1 error codes if boiler fails to fire a. No gas b. Gas inlet pressure too high c. Mechanical minimum or ignition sequence gas pressures too low d. Ignition electrode broken or earthed e. Gas valve malfunction a. Check mains supply b....
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Maintenance instructions tr05a140.B1107 54 6.9 parts lists 6.9.1 main components code description 40200069 primary exchanger isotherm. 4+1 3+3 25kw 12240045 pump rsl 15/5-3-ku-clf6 w/open c1+c3 46270044 condensate trap 50360067 electronic gas valve 40360068 venturi 20370032 fan px128/203 230v/50hz -...
Page 57: 7 Optional Controls
Optional controls tr05a140.B1107 55 7 optional controls 7.1 external controls, programmers and room thermostats all external controls used with this appliance must be zero-volt switching only! If mains voltage, i.E. A switched live, is fed to the control terminals the appliance will not function and...
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O p t io n a l c o n t r o l s t r 0 5 a 1 4 0 .B 1 1 0 7 5 6 7 .1 .2 s -p la n w ir in g s c h e m a tic zero-volt switching circuit add more valves & programmers as required permanent live boiler terminal block heating zone hot water cylinder cylinder thermostat room thermostat 2-port zone valves ...
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Installation, commissioning & servicing record tr05a140.B1107 installer & commissioning engineer details installer details company name installation date address corgi registration no. Corgi id serial no. Commissioning engineer details (if different from installer) company name installation date add...
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Installation, commissioning & servicing record tr05a140.B1107 commissioning procedure information for all boilers has the system been flushed in accordance with the boiler manufacturer’s instructions? Yes no what cleanser was used? Has an inhibitor been added? Yes no which inhibitor was used? For ce...
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Installation, commissioning & servicing record tr05a140.B1107 service 1 date: service 2 date: engineer name engineer name company name company name tel. No. Tel. No. Corgi id serial no. Corgi id serial no. Comments comments signature signature service 3 date: service 4 date: engineer name engineer n...
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Warmflow engineering company limited lissue industrial estate, moira road, lisburn bt28 2rf tel: 028 9262 1515 fax: 028 9262 0869 warmflow customer care centre uk 028 9262 1515 roi 048 9262 1515 email service@warmflow.Co.Uk the technical data and measurements are provided for information purposes on...