Download Vaillant VCW 25 Specifications
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Instructionsfor Installation and Servicing Vaillant Combined appliances for heating and domestichot water VCW2Ol1T3 W GC-No.47 04403 VCW2511T3 W GC-No.47 04405 VCW-sine18 T3 W GC-No.47 O4401 Centralheating Domestichot water This aoolianceshall be installedin accordancewith the relevant Codes of Practiceby BritishGas or by an authorizedinstaller C O R G Im e m b e r ) These instructions should be left near the gas meter when the installation is completed. 1 lntrcduction Contents P4e1 . lntroduction 2 . Construction of aPPliance J. Generalreouirements 4 . lnstallation of boiler Water circulation system Commissioningand testing 7. Assembling 8 . Servicingof combi heater q Foultfinding 1 0 . Short list of ports 1 1 .Technicaldata 2 2 4 ^l ;\ ;; ,; 46 61 64 The Vaillant csnbi boiler is a wall-rnqrrH natural draught open-flued (or in the case d VCW-sine, room-sealed) boiler with buifr it instantaneous domestic hot water heater, "TechnicalDda-. Outputratingsare shown in The boiler is designed for use in a sealed c open vented system with pumped circuldin ahd includes the instantaneous hot w& sYSIem. Circulatingpump,expansionvessel (forseald system only), terminal box, control and sdetf devicesare providedwith the appliance. Note to Installers ln hard water areas we recommend the d supply to the appliance is via a scale reducer. of ApPliance 2 Construction -24 9 11 23 22 14 18 19 21 o N 3 trin 2 I o l Fkrcorinection 2 Down draught diverter 3 Sensorof overheat cut-off device 4 Mainheatexchanger 4a Combustion chamber 5 Main hrmer 6 Gasgovernor 7 Flowswitch 8 Differential valve 9 DC solenoid 10 Fbwthermometer 11 Pump with automaticair vent 12 Pressuregauge \a- l 1 3 Terminalbox 1 4 Switchboard (mainswitch, heating switch, domestic hot water switch) 1 5 Domesticheat exchanger 1 7 Flowthermostat ' 1 8 Pressure relief valve 1 9 Service cock 20 Gas service cock 2 1 Overflow (optional extra) 22 Push button start 23 Push button stop 24 Pilot burner 25 Piezo unit air vent points o o '6 = o 3 Generalrequirements cP 342 Centralizedhot water suPPlY 3.1 Related documents The installationof the combi boiler must be in accordancewith the relevant requirementsof the Gas Safety Begulations.),buildingregulations, l.E.E. Regulations,and the byelaws ot the localWater Undertaking. It should be in accordancealso with any relevant requirementsof the localauthorityand the relevani recommendations of the following British Standard Codes of Practice: CP 331 Installationof pipes and meters for lown gas, Part 3: Low Pressure installation pipes. BS 5376 Selectionand installation of gas space heating(1. and 2. family gases). Part 2 Boilers of rated inPut not exceeding60 kW. BS 5449 Central heating for domestic oremrses. Part 1 Forced circulationhot water syslems. otherthan Part2 Buildings dwellings. BS 5440 Flues and air suPPlY for 3.2 Location 3.2.1 Vcwqjle (8.F. APP|iance) The locationdhosenfor the combi boiler must oermit the provisions of a satisfactory flue ierminal. The location must also provide adequatespacefor servicingand air circulation around the heater. The combi boiler may be installed in any room, although particular attention is cjrawnto the requirementsof the l.E.E. Regulations and, in Scotland, the electricalprovisionsof the buildingregulations, with respect to the installationof the combi boilerin a room containinga bath or shower. of the combiboilerwillbe Wherethe installation in an unusuallocation,specialproceduresmay be necessary and BS 5546 and BS 5376 : 2 give detailedguidanceon this aspect. A compartment used to enclose the combi boiler must be designed and constructed specificallyfor this purpose. An existing cupboard or iompartment may be used provided that it is modifiedfor the purpose. Details of essential features of cupboardi compartmentdesign includingairingcupboard instdllationsare given in BS 5376 : 2. Part 1 Individualdwellings, appliancesof rated input not ding 60 kW (1. and 2. familY Part1 Flues Part2 Air suPPlY. B S5 4 4 6 : 1 9 7 9 Installationof gas hot suppliesfor domesticPurPoses We liketo drawyourattentiontothefactthd connection for the filling or replenishingol a sealedprimarycircuitfrom a supplypipe is can ditionalupon a water undertakingseekingaa obtainingconsentfora relaxationotits Byeh 3 and 8 (1)from the Secretary of State. .) Gas Safety Regulation,1972: It is the law that all gas appliancesare ins{d by competentpersons in accordancewith t: above regulations.Failureto installappliara , correctlybould lead to prosecution.This b L your own interest and that of safety to erisG ihat the law is compliedwith. 3.2.2 VCW (O.F. APPliance) The locationchosen for the combi boilernrrsl permit the provisionof a satisfactoryflue ad bdequate air supply. The location must fu provide adequate space for servicingard * circulationaroundthe appliance. The combi boilermust not be installedin a rqq containing a bath or shower. In addition,it b recommendedthat the combi boilershouldrd be fittedin a bedroom.Where the installationd the combi boilerwill be in an unusualposilb\ special proceduresmay be necessaryand BS 5'326:2 and BS 5546give detailedguidanceot this aspect.A compartmentusedto enclosete combi boilermustbe designedand construec specificallyfor this purpose. An existingopbbard or iompartment may be used provided that it is modifiedfor the purpose. Details of essential features of cupboard compartmentdesign includingairingcupboad installationsare given in BS 5376 : 2. 3.3Gassupply the availabilityof an adequatesupplyof gas. 3.3.1Servicepipes atthe An existingservicepipe must not be usedwit> Thelocalgasregionshouldbeconsulted planningstagein orderto establish out prior consultationwith the local gas regiorl installation 4 3.3.2 Meters 3.3.3 lnstallation pipes A gas meter is connectedto the servicepipe by Installationpipesshouldbe fittedin accordance the local gas region or a local gas region with CP 331 :3. contractor. Pipework from the meter to the combi boiler An existingmetershouldbe checkedto ensure must be of a adequatesize. Do not use pipesof that it is capable of passing an additional a smaller size than the combi boiler gas 2.95 ms/h (106 CFH) before the VCW 20 connection. (or 3.38 mslh(122 CFH) beforethe VCW 25 or The complete installationmust be tested for 2.47 melh(89 CFH) beforethe VCW-sine18) is soundness as describedin the above Code. installed. 3.4 Flue system Detailedrecommendationsfor fluing are given in BS 5440 : 1. Thefollowingnotesare intended to give generalguidance. \=i= 3.4.1 VCW-sine (B.F. Appliance) The boiler must be installed so that the flue terminalis exposedto the externalair. Terminationshould be on a clear expanse of wall; the terminal being preferably not less than 600 mm (2 ft.) awayfrom acorner, a recessora projecilon. Do not install the terminal: a) Within 300 mm (1 ft.) measured vertically from the bottomof an openablewindow,air vent, or any other ventilationopening. b) Within 300 mm (1 ft.) above adjacent ground level. c) Within 600 mm (2 ft.) of any surfacefacing the terminal. d) lmmediatelybeneatheaves or a balcony. Where the lowest part of the termlnal is less than 2 m (6,6 ft.) abovethe levelof any ground, balcony, flat roof or place to which people have access, the terminal must by protected by a guardof durablematerial.A terminalprotective guard is availableas an optionalextra with the combi boiler.The air inleVproductsoutlet duct and the terminalof the boilermust not be closer than 50 mm (2 in.) to combustible material. Detailed recommendationson Drotectionof combustiblematerialare given in BS 5440 : 1. 3.4.2 VCW (O.F. Appliance) Detailedrecommendationsfor fluing are given in BS 5440 : 1. The followingnotesare intended to give generalguidance. The cross sectional area of the flue fitted to the combi boiler must be not less than the area of the flue outlet of the appliance.An adapter is suppliedto allowthe fittingof 125 mm steelflue pipe or 125 mm lightasbestoscementflue pipe. When fitting flue pipes a split socket connector must be fitted to ensure easy disconnection of the flue pipe (see page 13 f i g .1 6 ) . Flue pipes and fittings should be constructed from one of the followingmaterials: a) Asbestoscement, b) Aluminiumor stainlesssteel, c) Cast-iron acid-resistant vitreous enamel lined. lf double-walledflue pipe is used it shouldbe of a type acceptable to British Gas. lf a chimneyis used it preferablyshouldbe one that is composedof or lined with a nonporous acid-resistant material. (Chimneys lined with salt-glazed earthenware pipes are acceptableif the pipes comply with BS 65 and 540 : 1.) A flue pipe constructedfrom one of the materialsin a) to c) aboveshouldform the initial connection to lined chimneys. Where a chimneyis to be usedwhich is not composedof or lined with a non-porous acid-resistant materialit shouldbe linedwith a stainlesssteel flexibleflue liner or any other liner that is of a type acceptableto BritishGas. The internaldiameter of the liner must not be less than shown in the technicaldata and the number of joints mustbe kepttoaminimum.lf thefluelinerisnot to be connected directly to the combi boiler draught diveder a flue pipe which is constructedfrom one of the materialsin a) to c) above shouldform the connectionbetweenthe draughtdiverterand flue liner. Before connecting the combi boiler to, or inserting a liner into, a flue that has been previouslyused, the flue must be thoroughly swept clean of any soot and loose material.lf a register plate, restrictorplate, damper etc. is fitted in the flue, it must be removed before connectingthe combi boiler to, or insertinga liner into,the flue. The flue should terminate in accordancewith the relevant recommendationsgiven in BS 5440:1, table4. A terminal of a type that has been tested and found satisfactory by British Gas should be fittedat the flue outlet. The point of termination must not be within 600 mm (2 ft.) of an openablewindow,air vent or any other ventilationopening. c 3.5 Air supPlY Detailed recommendationsfor air supply are given in BS 5440 : 2. The followingnotes are intendedto give generalguidance. minimum effective area of permanent air vent(s) is specifiedbelow and is relatedto the maximumrated heat inputof the unit. cmz 108 130 Appliance vcw20/1 vcw25/1 in.2 16 20 3.5.1 Room or internal space air supply The room or space in which the boiler is located must have a permanentair vent' This vent must be eitherdirectto the outsideair or to must an adiacent 'have room or internalspace which a permanent air vent of at least itself i-n" same sizd direct to the outside air. The The balancedfluedcombiboiler,VCW-sine, doesnot requirethe roomor internalspaceto airvent. havea oermanent 3.5.2 Cupboard or compartment air supply Where the combi boiler is to be installedin a cuoboardor compartment,permanentair vents are required (for cooling purposes and in the case 6f open flued appliances also for combustionand flue dilution)in the cupboardor compaftment at high and low level' These air vents must either communicatewith the room or internalspace or be directto outsideair. The minimumetfectiveareas of the permanent air vents required in the cupboard or compartmentare specifiedbelow (Tab. 1) and are ielated to the niaximum rated heat inputof the unit. Air vent areas Pos.of air vents High Level LOW Level VCW-sine 280 320 235 {42) (50) (36,5) Airdirectfrom outside (inr) cm2 I (21) 140 (25) 160 (18,5) 120 vcw20/1 vcw25i1 VCW-sine 560 640 ,235 (84) (100) (36,5) 280 320 120 Airfromroomor space internal (inr) cmz , vcw20/1 vcw25/1 (42) (50) (18,5) Tab.1 Note: Both air vents must communicatewith the same room or internalspace or must be both on the same wall to the outside air. Where cupboard or compartment air vents communichtewith the room or internalspace the room or internalspace must itself have a permanentair vent(s)as specifiedin 3.5.1. 3.5.3 Effect of an extract fan lf there is anv tvpe of extract fan fitted in the oremisesthere i6 the possibilitythat if adequate iir inlet area from outside is not provided ipittag" of the products from the open flued combi boilersflue could occur when the extract fan is in operation.Where such installations occur a spiilagetest as detailedin BS 5440.: 1 must be carriedout and any necessaryactlon taken. 3.6 Water circulation system Detailed recommendations for the water circulationsystem are given in BS 5376 :2' BS 5449 :1 (Jorsmall bore and micro bore central heatinq svstems) and CP 342- the following notes ire of particularimportance.Pipework not forming pbrt ot the useful heating surface should belnsulated to help prevent heat loss and possiblefreezing,particularlywhere pipes are run through roof spaces and ventilated underfloorsPaces. Draininq taps must be located in accessible which permitthe drainingof the whole oosition-s svstem includingthe combi heaterand the hot water system. Dlainingtaps should be at least 1/2 in. nominalsize and be in accordancewith BS 2879. 6 F , \- 3.7 Electrical supply Wiring external to the combi boiler must be installed in accordance with the l.E.E. Regulationsand any local regulationswhich apply. The combi boiler is supplied for 22O/24OV, 50 Hz.Fuseratingis 3 A. Thecombiboilerhasto be connected directto the mainselectricity supplyusingthe internal terminalbox. Forwiringinstructions seeparagraph 4.7. 4 lnstallationof boiler (16 in.) must be available at the front of the appliance to enable the combi boiler to be servrceo. Serviceclearanceof 150 mm (6 inches)either side is reouired. For the open flue type appliancesVCW 2011 and 25/1 an additional clearance is requiredfor the flue. The combi boiler is supplied in 2 cartons,one containingthe boiler,the other the installation accessories. An additional cartoncontainingthe terminal/ductassemblyis deliveredwith the balancedflued appliance. 4.1 General The combi boiler is to be wall-mountedand a verticalflat area of wall is requiredwhich must measureas shown on templateThis area does not include clearance for installationand servicing. lf the appliance is fitted on a wall of combustible material, the wall should be protected by a sheet of fireproof material. In addition.a minimum clearance of 400 mm o o c o 6 >oFO. (U A B vcw20/1 vcw25/1 1095mm 1 1 6 1m m 130mm 125mmwithadaoter 22mm 15mm D 'l00mm 107mm Er K weight Fig.3 Alldimensions in mm 1014mm 1080mm Electricalmains connection 59 kg 60 kg distancerequiredto ) Minimum removeexpansion vessel. Installation mayrequire anotherdistance. 7 ! ; Fig.4 4.2 Fluing Forthe installationof the flue set (wallcase)ot a combi boiler, we reter-to rne -in.t"llation room sealed instructions No' 806901 .!-o"t"i" iniluded with everyflue set. 4.3 Connection A oeneral view of pipeworkfor gas and water coinection is given in fig. 5. The following procedure describes the installation. The wall distance(to the finishedwall) of pipewoit<toi gas and hbatingsystem is.50mm and 40 mm for domesticwater PiPework' 8 in mm Alldimensions t 1. Compression union (flow of heating svstem) z. S-ervicecock (flow of heating system) 3. Domestichot water connection 4. Union (gas) 5. Gas service cock 6. Cold water connectionwith shut-offvalve 7. Servicecock (returnof heatingsystem) 8. Over flow (optionalextra) 9. Pressure relief valve 10. Compression union (return of heating system) 11. Connectionsupport 23. Frameof appliance(lowerconnection)' ,,4 I 4.3.1 lnstallation aids 4.3.1.1Open flued combi boiler After fixingthe connectinggroup to thewall put the template in positionancl mark posltlonsoI fixing holes. The type of fixing used will depend on the type of wall. II **!**o 4.3.1.2Roomsealedcombi boiler assembly, After installinqthe terminal/duct onthefixingbolts(1) anddrill hanothetempi-ate the5 holeswith8 mm(5/16inches)diameterto fit the connectinggroup.Use the alternative fixingholeswherenecessary. rl fl I | + 1 - I 4.3.2Domesticcold and hot watel connection - Flush out all loreign matter from the supply pipe before connecting to the connectinggrouP. - Fit the domesticmainswater pipe to the union(2) and the riqhthandcompression h5twaterpipeto the lefthandcompression union(3). ln hardwaterareathemainssupplyto union (2)shouldbe viaa scalereducer' - bhect domesticwatersystemfor soundness. amaximumworking boilerhas N.B.Thecombi oressureof 10 bar. lf water pressure bxceedsthis a pressurereducingvalve willhaveto befittedto coldwaterinlet. 10 ll )l II {33 Gonnection of heating system Fledirtgsyslemflow and returnshouldbe in 2. rrtn copper pipe and connectedto the cqrtecting groupas shownin fig. 9. Ftl lhe heatingsystemandtestfor soundness. I I I t 4.3.4Pressurerelief valve and overflow The pressurereliefvalve,requiredfor a sealed system,is includedintothe connectinggroup. - Screw in the overflow (4) below the pressurereliefvalveintothedrainline. (Tobe availableas an optionalextra.) I 4.4Fittingthe appliance Closeservicecocks(5),unscrewunionnuts(6) and take off the olive-shapedplastic plugS. Refit union nuts (6) with brass'compr6ssi-on rings (7). Close mainswaterservicecock (8) andunscrewthe unionnutF(9). *-A-6 4.4.1 Open flued aPPliance Unpack boiler from carton and remove side oarieislas in 8.1'1.),lint arrestor(as in 8'2'2) inO pait ing aids as well as plasticcaps.from the ionneciions. Insert the appliancewltn tne connection tubes downwards into the comoiession unionsof the servicecocks and hang it on to the bolts(1)and fasten screws (10)' unions(6)andunionnuts Fastencompression washers(11)' attached thb using ig), 4.4.2 Balanced f lued aPPliance Unoack boiler from carton and remove side Janels(as in 8.1.1.) and packingaidsas wellas blastic baps from the connections.Fit the flue buct (20) irtitntne 2 sheet metal screws (22) to the t;le6copic duct (16) of the terminal/duct assemblY. Insertthe appliancewith the connectiontubes downward iirio the compressionunions of the service cocks and hang it on to the threaded bolts of the wall case (1), fig. 14. Fasten nuts, compressionunions(6, fig. 13) and unionnuts is, iig. 13) using the attached washers (11,fig.13). 20 21 F i g .1 4 12 1 Fixingbolts 16 Telescopicduct 19, 22 Sheet metal screw 20 Flue duct 2'l Flue bend 45 Gcconnection Frtthe gasservicecock(5) to the appliance. Cleil out all foreign matter from the gas s.Dpty pipe before connecting to the service cock! Connectthegassupplypipeto theservicecock andtighten. F--i a 4.6 Flueconnection (openflued) Insertflue intothe draughtdiverterafterfitting the adapterprovided. A split socket connector must be fitted to ensure easy disconnection of the flue to simplifyremovalof themainheatexchanger. 21. Fluepipe 22. Draughtdiverter 22.aCollarotthedraughtdiverter 24. Adapter 25. Splitsocketconnector a 4.7Electricalconnections Vaillantcombiboilersarecompletelywired. lt is onlynecessary to connecttheelectrical mains andtheroomthermostat.Connectto220/240v 50 Hz.electrical sgpplyfused3 A. Warning!Thisappliancemust be earthed. Afterremoving theterminalboxcoverconnect the mainsto theterminal(c)of theappliance in the manner indicatedbelow. A cardboard labelshowingthe correctmainsconnection to the terminalsis in the terminalbox. Please removebeforeconnecting. Do not connectthe electricalsupply to the pump terminals(b). Full wiring diagrams for various control schemesareshownintig.21Io 24. t t t l l l r i 4.7.1 Connection of the mains cable As shown on the figures the live conductor *nicn is colouredbrown must be connectedto the terminalmarked with a L on the appliance inO to tne tetminalmarkedL or colouredred on the Dluq.The neutral wire colouredblue must 6e ioni"ct"O to the terminal markedwith a N on tne aoptianceand to the terminalmarked N oi coioureOblack on the plug' The earthwire colouredqreen and yellow must be connected i" rn" otine two teiminals marked O on the "opiiin"" and to the terminalmarkedwrthan E oi svmbol O or coloured green or green ano vellow on the plug. lf no room thermostat or iimer is installbd,-terminal3 and 4 must be linked. a. Fuses 2 A (delayaction). b. Terminalsfor pump regulating' i- Terminalsfor hpplianceinput connections' 1 @@_a ..'\L*= -j LEf,-l @a Fig.18 Connection of Vaillant room 4.7.2 -thermostat with clock (no' 394) Connectionof room thermostatis made to the terminiri g anO4. lt is recommendedto installa Vaillantroom thermostat(RT)with accelerating resistance. The room thermostat must De inJiiiteo on an inner wall which is influenced neiiner Ov current of air nor by the sun, in the livinq rooin. Duringthe installationof the room therftostatthe manufacturer'sindicationsmust be followed. For the sake of economy and iotfurt the Vaillant combi boiler should be requlated by a room thermostat with icceleiating resiitance. lf the room thermostat is not connected,to operate the heating system ior i"iting purposes'afterthe installation,the ,nit "an bi op6ratedby provisionalapplication oi a OriOgebetween ihe terminals 3 and 4' Wfren tfrE room thermostat is wired in this bridgemust be removed. 4.7.3 PumP control The pump may be controlledin one of three ways (see fig. 20): SettinqI (as suPPlied) For-use with clock and room thermostat systems. Pump is switched off by clock or room thermostat. Settingll For"use with thermostatic radiator valve svstems. Pump is switched off by clock or o'asvalve switih when gas valve closes' selttingttl Purip runs Permanently and affected bY external controls. is t Sz not i 14 1,7, Thcrmostatic radiator valves l$rere TRVs and a clock are used the ilibfrirg side of the clock is connected betreen teminals 3 and 4. lYhereno clockis useda wire bridgemustbe insertedbetweenlerminals3 and 4. Setthe pumpcontrolto positionll. VCW-Terminal RANDALL TimeSwitch 103 Do not link terminal3 & 6 VAILLANT Roomthermostat VBT378 0 Fig.21 VCW-Terminal N Mains L Supply 24OV/5OHz I SWITCHMASTER 300TimeSwitch a REMOVE O VAILLANT Roomthermostat VRT378 0 1) Link N and 2 2) Link L and:4 N Mains L Supply 24OVlsOHz 3 15 HORSTMANN 125 COFONET Time Switch Do not link terminals Land5! VAILLANT Foomlhetmostat vRT 3 78 N t.in" L SuPPIY J 2r0v/50H2 3 o l':- Fig.23 O VAILLANT Roomthermostat VRT 378 0 16 N Mains L SUPPIY + 24ovl5oHz B E -9- 6 = O E;E 9 p 5 "9=i ; E$s a a E l I I Ib o .o (, CD lo lt^ a cl c o l 988x: o* o' t 3 (o I o(g F i i p o c o o a? o o 3 o ' o = ",1; E Y r() AI .st, tt E o o o c '= 15 14 13 21 '12 n 23 24 25 77 26 11 10 9 I 7 6 5 70 71 73 54 5:l 30 2A n 31 58 /-ffi 61 7A 46 1 0t[|il[[|ll 32 Fig.26 1 service cock 3 flow switch 4 thermostaticelement 5 gas inlet 6 automaticvalve 7 pilot adiustmentscrew I switch box/FFD 9 oush button start 10 pilotvalve 11 push buttonstop 12 thermo-magnet 13 micro switch 14 thermo-couple 15 pilotburner 18 16 sensorof overheatcut-offdevice 17 main heat excnanger 18 air ventingscrew 19 expansionvesset 20 main burner 21 gas governor .. 22 mainburneradjustmentscrew i3 double-stagemain burnervalve 24 venturi 25 differentialvalve 26 DC solenoid i8 expansionvessel pressurecontrol 29 pump -'_-43 N--.a.-:.*. water o"'"""'ic 3?:li"#3[?t!l3ll circutr heating i i 32 39 mainswitch 41 terminal tlo"o"* X3 rn"rto""' hotwater 58 micro-switch 59 watersedlon . 60 coldwaterinlel 61 watergovernor. 63 hotwateroutlel switch 3e!3il'J3-:Y':ilvarcr control 70 electronic 71 NTCresistor *"*"' "1.1H,$3#3f;'ftL 1? systembypass 78 $i[#s$:rrtt:"' t. 53 micro-switcn ll micro'switcn 54 79 relaY 19 5 Watercirculatingsystem 5.1 General The combi boiler is suitable for use on most miniboreand microboresystems. It is recommendedto use copper tubing to BS 2871 :1for water carryingPiPework. The use of horizontal pipe runs should be avoided whereverpossiblein order to prevent air collectingin the system. lf horizontalruns are unavoidablethe pipes should rise upwards towards a vent point. For qeneral quidance reference should be mide to ihe British Gas publication INSTALLATION MATERIAL AND DOMESTIC SPECIFICATIONS FOR -, CENTRALHEATINGAND HOTWATER B :1. BS 5449 and BS 5376:2 to and 5.1.1SinglePiPesYstem The heat emittersare installedon a closed circuit.The necessarywaterquantityfor every mustbe ensured.This heatemitter(radiator) can be done for instanceby using suction of theradiators. fittinosinthereturnconnection on the sizesshallbe calculated The-radiator aroundthe distribution basis of temperature circuit. Fig.28 5.1.2Two-pipe system The radiatorsare installedparalleland the flow temperature therefore is the same for every radiator. Typicalcentralheatinginstallationare shown in the followingfigures. NOTE: 5.2 to 5.5 are applicableto both open and sealed systems. N.B. The primaryfillingpoint may be placedat any convenientpoint on the circuit. FillingPoint Fig.29 20 S2Gontols Vdilt cofiti bcilers are ready for connecting oleebcLft:d mains. W$Gn conhds (24OV) may be connected as sfwn h figures 21 to 24. 53 lrolating valves The +dianoe shall be installed with isolatinq (service cocks) as described unde-r dws 4-3_3. 5.'tGirculating pump The cirolating pump is included into the combi boiler. The remaining conveying capacity can betaken from the diagram. SssYstem by-pass A system by-pass is included into the combi bdler. 800 176 1000 220 1200 264 14c,0 308 1600 L/h 352 cPH 5.6 Openvented system lf it is requiredto usethe combiheaterin ooen systemsit is possibleto do so without'anv modification to the combi heater. W6 recommendto fit the expansionpipe(2) at the isofationvalve(no.7,tig. 12)wherenormallv the pressurereliefvalveis fitted.The relevani BritishStandardsandCodesof Practiceas well a: otl.gr requirementsinvolved(see also 3.1) shouldbe strictlyobserved. Minstatichead:0.15bar(5'water) Maxstatichead:2.0bar(67'water) see BS5449clause24.1 2 expansionpipe 3 expansioncistern 7 overflowpipe Fig.31 21 5.7Sealedsystems Sealed systems do not requireleed and openventsetc'only gooo cisterns, exDansion ouitiWraOiatorvalve'sand fittingsshouldbe detrlmenlal Jsedin orderto preventexcessive topping-uP. 5.7.1Pressureleliefvalve This is requiredon all sealedsystemsand is shownin 4'3.4' connected'as 5.7.2Pressuregauge Thisis factoryfittedto theboilerandshowsthe circuit. in thePrimary pressure 3 5.7.3Expansionvessel into vesselis incorporated A 15 litresexpansion ihe combib6ilersuitablefor a sealedheatingiuit". with a maximumwater contents of 260litres(57.2lmP.galls') lf thenominalcapacityof thebuilt-inexpansion vesselis not sufficientfor the heatingsys,tem. of old in case of modernization itor-instance iioen Jvstems)an additionalexpansionve-ssel of the to the sideconnection cin Oeinstatt6d ieturn service cock in connectionwith the pressurereliefvalve. Fig.32 5.7.5 Pipework 5.7.4Fillingand makeuP All oioeworkshall be securelysupported,shall a via The svstemshouldbe filledwith water where possible' lillingpointfittedat a convenientpoint run'n'eatlyand be concealed seoar6te on' the neati-nbcircuit.Where local Water Authority Regulationallows, a temporary connectionto-the mainsmay b,eused' The connectionmust be removeclwhen lllllng ls completed. Where local Water Authority Reqirlation does not allow temporary a sealedsystemfillerpumpwith corinection, breaktankmustbe used.The heatingsystem witt not be filled automaticallyfrom the domesticside. ln principle,sealedsystemsdo not require faciliti6s,but experiencehas waier mat<e-up shownthatsomemake-upmaybe necessary' Methodsof fillingsealedsystemsaregivenin A of BS 5376:2. appendix 22 6 Cornmissioning and testing 6, 1 El€ctrical installation r-e,'rinary electricalsysiem checks to ensure +€sflcal safety shall be carried out by a :r,mpetent person. Those checks are outliired r tne INSTRUCTIONSFOR BR|T|SH GAS IiIULTIMETER. t t 6.2 Gas installation Tne whole of the gas installation,includinqthe reter. should be inspected and testej for soundnessand purged in accordancewith the iecommendationsof Cp 331 : 3. 6.3 Water circulation system The whole oJthe systemshould be flushedout wtrn Dotncotd and hot water. Ensureall valves are open. With the combi boilerfitted,the system should be fiiled and air locks cteared.V6nt tnJOoifei throughthe 4 vent pointsshown ln tiq. iand'2. Loosenthe black cap on the automaiicair vent oy 1-z turns. Vent all heat emittersand check for.water soundness.On a sealed svstem fiti untilthe pressuregauge registerst.s iraiizr.S PSI). (The system should be filled with water either from a sealed system filler pump with a break or by a method of filling given in BS La_lK. 5376 : 2, appendixA.) Checkoperationof safetyvalve.Releasewater Tromrne systemuntilthe initialsystempressure oL.-t,zoat ts atatned, taking into account anv otnerence.in height between the pressur6 gauge and rhe point at which the higtiest heat emtnerts connected_ Fig.33 6.4 Lighting the combi boiter The first lightingof the applianceshall be done oy a quatttiedfitteronly.He shallalso give clear verbat instructions to the user on how to operatethe combi boiler,controlsand systemi generally.Light the combi boiler as described separatelyin the "lnstructionsfor use,,. 6.4,1 Gas soundness Test for gas soundness around boiler qas components using sense of smell and l6ak detectionfluid. 6.4.2 Main burner pressure Pull off the plug of the NTC-resistorand test the matn Durner pressure at the main burnei pressuretest point. 23 6.4.2.1NominalheatinginPut mustbe as follows: Thepressure mbar(8.08in' WG) intetbressure:20 mainburnerpressure(coldandhot): 9.0mbar(3.61in.WG) vcw 2011 9.0mbar(3.61in.WG) vcw 2511 10.6mbar(4.26in.wG) 18 VCW-sine The apolianceis regulatedat factoryto the .b'ti"5i neating influt. Thereforeit is not n"lJ""urv to a[6r thbsettingof.inputor output duringinstallation' "itne g"d gouernor 1 2 3 + 5 6 7 screw pilotadiustment pilotgasfilter DCsolenoid testPoint mainburnerPressure gasgovenor blockingPlate inLipti.irte testpoint(nearrearplate) 6.4.3Flue Checkthatthereis no spillageof products,of fromthedowndraughtdiverterby JomOustion carryinqa spillagetest as detalleoIn t:D il6' i r. thppiicaoteonly to open{lued ol llamesIn Checkappearance aooliances.) lii,irl"-"iihrtish thatihereis adequateair for LturitLn, checkalsoasoutlinedunder3'5'3 ii'tn"l"li lriv tvpeof extractfan fitted' B 6.4.5Flow thermostat Checkthe flow thermostatand all automatic Jontiofsare operatingsatisfactorily'Readjust settings. controlsto appropriate 6.5Watersoundness Allow the water system to reach maximum woif<inqtemperatuieand examinefor water iornon""...ihe systemshouldthenbe turned offind rapidlydrainedwhilestillhot'Thewater iu.t". shouldagainbe filledandclearedof air 6.4.4Flametailuredevice idcis. Sealedsistems shouldbe adjustedto devic.e failure flame the of operation Checkthe initialsystemdesignpressureof 1,2bar' will the device the that ensure to "'"'ini donoiuoiler forwatersoundness. Examine 60 within burner main the "iir,li "tt sit to seconos. Please contact your senticing company' 6.6User'sinstructions nearestVaillint office oryour local gas for use to the userfor Vo-u-r Handthe instructions region, l"T"niio"unOinstructin the safeoperation.of ii. aooriince. Advise the user of the oi"cauiibns necessaryto preventdamageto ihe svstemand to the buildingif th-esystem JoLJ'not remainoperativeduringfrost conditions. Note: Leave installation and servicing at the meter' instructions For continued efficient and safe operation, "iirt-viiiii"ni ippliance should be serviced liLaiion"e a'vearbv a qualifiedservicing company' It is important and strongly re-comm.ended that ariangementsare made for a -!44!!!!9 ilt cA-sr6ereLtwith a qualified servicing F i g . 3 5 to ensure regular servicing' ififfiv 24 o o N = o o 7 Assembling 0 ieotace the plug to the NTC (Negative :ernperature Coefficient) resistor before :ssembling. = () a 7.1Lint arrestor(openflued appliance) Tofitthelintarrestor hangit intothefrontsideof thelowerretaining frameandclipit againstthe appilance. 7.2 Side panels Push the 2 side panels from the front onto the boilerand screwto the upperand lowerframes with two pairs of captive slotted screws. lf the door isre^quired to open from the right see section7.6. o += o Fig.38 25 7.3 Screen Plate Positionthe left hand edge of the screen plate unOertne side panel.Pressthe slideunderthe eJoe ot tne riqhthandsidepaneland alignwith the-slotsin the screenplate.Securethe screen otit" *itn 3 screws as indicated in fig 39' ileolace the thermostatknob' 7.4 Front Panel Press the front panel including the grey enameledcentre sbction onto the boiler' the 4 bolts engage in the spring-boltedsupports' 7.5 Door The door supports are attached at the right hand side panelof the appliance(dooropening from the left).The door is fittedas follows:place the door into the upper supportand fix to lower supportwith the hinge screw. 26 I 6 Changing door attachment -r€ roor can also be fitted to open from the -i:--. as describedin the following:Changethe -rc,er.and the lowerdoor supportfrom the right -,ar'. to the left hand side panel of the :E€} an@. 7.7 Stickers Stickon - instructionssheet after filling in - serialno., - test point pressureand - date of commissioning - wiringdiagram to the inner side of the door as shown on fio.43. 8. Servicingof combi boiler $ - The combiboilershouldbe servicedat least oncea year.A servicecontractmaybe agreecl with BRITISH GAS or Your CORGI INSTALLER. 8.1Turningoff the combi boiler To servicethecombiboiler - Switchoff electricalsupply(1, tig.44). - Turnoff gas servicecock(3,fig.44),boiler isolatingvalves(4, tig. 44) and cold water shut-offvalve(5, tig. 44). @ e a-]r*Lrz I \,{\ @__ ta, 8.1.1Removingoutercase(fig.44) hingepin(b)and Removedoorby unscrewing oullinqdoor out and down. Removeupper banei Oy pullingoutwards.Removegauge jlanel bir iemovingboiler thermostatknob' 'screw over rockei switchesand loosening screws(c) and slidingrighthandpanelto the left. top and Removeside panelsby unscrewing buttomscrews(d) to clearinternalclipsand then pullingpanelsoutwardsand off' In the case of the balancedflued combi boiler VCW-sineremovethe 4 screwsand washers (A) to removecombustionchambercase as showninfig.45. {eir 'ry t 8.1.2 Drainingthe aPPliance (fig.44 and 46) When necessary,the appliancemay be drained as follows. - Open air vent (18,fig. 46) . - Drain appliance through draln nlpple (tr, fig. 46). - D-raindomestic heat exchanger via drain screw (C, fig. 46) as well as pressure relief vdlve (D, fig. 46) at the lower part of the water section. 8.2 Cleaning of burner and lint arrestor 8.2.1 Cleaning of burner 8.2.1.1Balanced llued appliances Removethe burnerby unscrewingthe retaining unionnut (E),the pilotairfilter(F),takecare not to lose the pilot inlector. Remove the thermo couple by pullingdown and taking off the high ten6ionlead from the ignitionelectrode. 28 L l,lrcrer the retainingscrews (T) and remove Cileanbumers, injectorsnozzlesand trcs. certbly with a light brushor a vacuum il CEE'. Fbsenble in reverseorder, replacingthe m-r bumergasketif necessary. Fig.48 82.1.2 Open llued appliance Remove bumers by levering off burner bar with a screwdriver. Remove thermo-couple probe by pulling downwards from pilot assembly so that probe disengaged from circlip. Remove pilot assembly.by unscrewing screw (F). Remove burner bar by unscrewing nut (E). Cleanburnersandinjectorswitha lightbrushor vacuumcleaner.Reassemble in reverseorder, replacingmainburnergasketif necessary. 29 8.2.2Cleaningof lint arrestor (openfluedaPPliances) Removethe lintarrestorby pullingdownward of the the partwhichis nearthe connections appliance. Cleanwiththelightbrushor a vacuumcleaner. in reverseorder. Reassemble 8.3 Cleaning of main heat exchanger 8.3.1 Balanced flued aPPliances Removeburneras under8.2.1.1. Slackenthe 2 screws holdingthe flue hood and slide hood up as far as possible. Remove sensor (3) of overheat cut-off device from pocket on left hand side of heat exchanger. Undo union nuts (G) on heat exchangerunionsand slackenlockingnuts (H) above them. Removeheat exchanger. Clean heating body especially fins carefully with hot waier, detergents and brush. lf necessary descale with propriety descaling aqent. Do not bend the fins. lf necessary, carefullywith screwdriver. st-raighten 8.3.2 Open flued aPPliance Remove burner assembly as under 82.1 .2. Slackensplit collar. Slacken the 2 screws holding the draught diverterand slide draughtdiverterup as far as possible. Remove sensor (3) of the overheat but-offdevicefrom the pocketon left hand side of the heat exchanger.Undo union nuts (G) on the heat exchangerunionsand slackinglocking nuts (H) abovethem. Removeheat exchanger' clean heatingbody and especiallyfins carefully with hot water, detergent and brush. lf necessary,descale with proprietarydescaling aoent. Do not bend the fins, if necessary carefully with screwdriver. st"raighten 30 L -:_Tovethe venturi -a-c connection tubesituatedin the riqht_ of the heatingO"Ov.b'nZci :,:.e ando-ring,cleanboreand-repla6" - -gcessary. ;_*;; =;lp9emble ..in reverse oroer, ensurino A:shers fittedin heat "".n",ig"i'r;;;X .are : J rlueductengagedin spigotin flr; 6rrn*;;;i 8.4Descalingof domesticheatexchanger 111:l]r_etcessarytodescatethedomestic-heat excnanger removethe tl .1"_.-:y'q "ndt-n"',i:",ru saus" i:Ji:?"T; -nscrewing the2 tubingnuts.For6et-tei;;;";i :o the connections. reriove the b;;;;e;;fi;; tne S retatning;;;ily =i:"^ p^y.unscrewing the 3 u.nion nuts(K) "io-ir,"'"2 -o_ .1?I--qy9 rarn lng_ screws(l). Descaleb,jr".ti" rlt"? descating agents :11e_: anOrinl-e ?yptoryetary arerwardswith clean water. 3ea:semble in reverse oroer using new /yashers. : 8.5 Cleaning of water section I?_-l"Toy.q. the water section unscrew the 'nrernat.. (N) and the external- (M)";"i;; connectionsand loosenthe screw (L). ":tess to theconnections unscrew i:^,,!:tl :ne towerretaining frame. Open the water section. Clean the water filter (O) or replace,if necessary'Check diaphragm tpj anO water governor (61), replace, if necessary. Reassemble in reverse order using new washers. Where stuffing gland needs replacingfit new too to water section,incorporatingnew stuffing box. of differentialvalve 8.6Maintenance Mark and disconnectthe two unions and screws(Q). unscrewthethreeretaining Ooen differential valve and clean. Check dihohraom and replace, if necessary. Check eaiv ruininq pin of diaphragmdisc in stuffing box. In casebi replacementof the stuffingbox' it is recommendableto replacealso diaphragm disc. Lubricatepin with suitablegrease. Mark and disconnectthe two controllines and clean by blowingthrough. Reassemblein reverseorder. Jt- Fig.58 32 . E-7Eryansion vessel (sealedheating system onlY) lnec* internalpressureof expansionvessel *nir*r shouldbe 0,7 to 0,9 bar' if heating is withoutpressure(black srstemof appliance gaugeat 0). Refillwith :'al of build-inpressure ar pump,if necessary. i { : . - -t i f 5 f I l_ ( i I 8.8Finaltests I o tf 8.8.1Finaltest heatingsystem o the open nipples and Closealldrainscrewsand 3 lf O servicecocksto refillthe appliance. a sealed svstem ensure the pressure is 1.2 bar to 6.3. Switchon electricity,turn on a-ccording qas andstartthe appliance as outlinedon the ;tickerattheinnersideofthef rontdoor.Check flame failuredevicefor correctfunctioning. Checkthe pilotflameand adjustwiththe pilot rate adluster (7) so that there are three seoarateflames.lf the flame profileis one larqe,looseflame,increasegas rate until 3 seiarateflamesdevelop,as shownin fig.60a' Replacepilotjet if necessary. for soundness. Checktheappliance Check all controlsfor correct functioning' reassembleouter casing of applianceas under7. s 8.8.2Finaltest electricalsystem Check - earthcontinuity polarity resistanceto earth according to INSTRUCTIONSFOR BBITISH GAS MULTIMETER. 8.9 Change of Pilot iet Disconnectthe pilottube from the pilot'Change pilotjet and washer and reassemblein reverse ordbr. In case of an open-fluedapplianceremovethe pilot assembly by unscrewing the retaining bcrew. Changb the pilot jet and reassemblein reverse order. Check connectionsfor gas soundness. 8.10 Change of thermocouple Disconnectthe retaining nut (R) and pull the thermocoupleout of the thermocouplesupport. Insert the new thermocouple fully into the support. (ln case of VCW-sine seal the thermolead into the bottom of the chamber plate by a specialrubberwasher).Connectthe retainingnut. 8.'l1 Change of sPark electrode (VCW-sineonly) Pull off the high voltage lead, remove the retainingscrew(S), removethe sparkelectrode and replace with the new electrode. Reassemblein reverseorder,ensuringthat the sparkgap from the electrodeto the flameshield is 3 m;, takingcare not to overtightenthe f ixing screw. ,,n[;5-o j 8.12 Change of NTC (negative temperature coefficient) Plobe Disconnect the AMP plug and unscrew the NTC probe. Reassemblein reverseorder' 8.13 Change of automatic air vent Drainthe applianceas under8'1 and 8.1.2. Unscrew the automatic air vent by hand. Reassemble in reverse order, screwing the automaticair vent in bY hand onlY. Open the lockingcap (LC) of the automaticair vent by 1 -2 turns. 34 \, |llf Change of flow switch or parts t-1f.1 Electrical isolation botde the appliance from the el6ctrical mains. Pr.fl off the plug (S1) by shifting the retaining (S2) top and bottom to the side. Egu6 8.14.1.1Ghangeof flow switch mirco switches Sorinqoff the protectivecover (SG).Unscrew (S4 or (S8),takeotf microswitchand remove the AMPplugs. in reverseorder. Reassemble Adjust the actuatinglever as outlinedunder 8.14.2.' 1. 8.14.2Removalol completeflow switch as under8.1and8.1.2. Draintheappliance Removethe 4 unions(S3) and the 2 screws (S4). Pult off the AMP tag (S5) of the NTC resistor. 8.14.2.1Change of flow switch stuffing box Remove complete flow switch as in 8.14.2. Unscrew retainingscrew (S9) and take off the micro switch assembly. Unscrew adiustment nut (S10), remove lever assembly, remove 3 screws securing top cover, unscrew stuffing box, remove both rubber seals and fit new seals, ensuring washer is fitted between the seals. Reassemblein reverseorder and adiust lever assembly of the cold flow switch as follows: Turn down the adjustmentnut (S10) slowlyuntilmicroswitchclosesthe redto brown circuitand make one more completeturn down. 8.14.2.2Change of thermostatic element Unscrew the 3 retainingscrews (S11) and remove the housing (S12). Reassemblein reverseorder, using new washers. 8.14.2.3Changing internalseals Removehousingas in 8.14.2.2. Bemoveseals R1 and R2 and replacewith new ones. Do not use any jointingcompoundor grease. 8.14.3Reassembling Reassemble in reverse order, using new wasners. Check - earth continuity - PolaritY - resistanceto earth accordingto INSTRUCTIONSFOR BRITISH GAS MULTIMETER. Note: positionof notcheson plug as shown. .to \" Af 5 Change ot piezo igniter (VCW-sine only) Elisconneclthe high voltage lead (pl) from the i.d bolt. Removethe retaining screw (p2) and remove the unit by springing the bracket. Reassemble in reverse onier, ensuring that krcding dimple in the bracket aligns wiih the dd in the piezo unit. fr= b4 8.16 Change of DC solenoid lsolate the appliance from the electrical mains. llolg.coloy.r code and puil off the AMp ptugs (Dl) from the micro switch as weil as the'Alrip dugs (D2) from the DC solenoid socket. Loosen the 2 retaining screws (Dg). Beassemble in reverse ordel. Check - earth continuity - polarity - resistance to earth a€cordingto INSTRUCTIONSFOR BR|T|SH GAS MULTIMETER. 8.17Changeof DCsolenoidmicro switch lsolatethe appliancefromthe electricalmains. NotethecolourcodeandpullofftheAMpoluoi (Ml). Unscrewthe 2 retaining - screwsiMi;. Reassemble in reverseorder. Check - earthcontinuity - polarity - resistanceto earth qcggrdingto TNSTRUCTTONS FoR BRtTtsH GASMULTIMETER. l l ri i 8.18Ghangeot pump 8.18.1Changeof completepump as under8.'l and8.1.2. Draintheappliance mains. fromtheelectrical lsolatetheappliance Openthe terminalbox of the pump.Notethe colourcode of wiringand disconnectpump cable. connection Unscrewthe automaticair vent(Pl ) by hand. the 2 controllinesof the Markand disconnect thetubingnuts valveby unscrewing automatic (P2). Loosenthe 2 pump unions(P3) and unscrewthe bracketfixingscrew(P4)andthe to unionnut (P5)at the righthandconnection the mainheatexchanger. 8.18.1.1Open flued boiler Take otf connection to main heat exchanger together with the pump as shown on fig. 75. Reassemble in reverse order, using new washer at the righthandconnectionto the maln heat exchanger. Screw in the automaticair vent by hand only. Check - earth continuity - polarity - resistance to earth according to INSTRUCTIONSFOR BRITISH GAS MULTIMETER. 8.18.1.2Balanced flued boiler Unscrewthe upperpump union (P3)and spring off the pump as shownin fig. 76. Reassemblein reverse order, using new washer at the right hand connectionto the main heat exchanger. Screw in the automaticair vent by hand only. Check - earth continuity - PolaritY - resistance to earth according to INSTRUCTIONSFOR BRITISH GAS MULTIMETER. 38 5. 8-18.2Changeof pump head onty Draintheappliance as under8.1andg.1.2. lsolatetheappliance fromthe mains. t-lpenthe terminalbox of the electrical prmp. fVoieit-e ggroyrcodeof the wirinsano'oisc[nn6ci .jr,L.',i iii! p:llp,_ connecrioncabie. un.,jr"* (p6)anop.urr otrp-ump.ijE"o] L"l:ll,lSscrews lHrJvJisy*siEb $":F:Ti_{{t,yiHl3lfl n^eassemble in reverseorder.Ta-ke;;;not to oamagethepackingring. Check - earlhcontinuitv - polarity _ .. resistanceto earth FoRBRrflsH 3iT'fl0flr,'#PTRUcT|oNS 0 8.19Changeof gas section "," $H:3}lFift?:dif"tj3,.iil?i,i!:ffi discorin ecti nstn6..i ilioii'i,fi 3i):fi:.{li"JJJ bytoosenins tnee ieiainiis;;""; i6fi"'o 8.19.1 Batanced flued appliance pirot assembrv i""Jl:;"J:TiH"","#J:"{t?il 8.19-2 Openfluedappliance pitotsuppon.by unscrewinq *ruy: the screw(G3)'andihe ,;i;.'fi;;; the l"_r3ll'.19 ihe a reiainiii'#;;: lAli'9y;^l"move (\rz+r,reptace valve seating, springi ;t". ;; inrev"'i"oio"i ,lsin'd fiffi3,l",3"assemble Checkconnections forgassounctness. \| 8.20Changeof gas governor 8.20.1Balancedfluedappliance gas sectionas in l-l:lgy" unscrew the 4 retaininc 8.19 and 8.19.1. i;;"";###1,3ffi_($3ln 3.'-T ?r." *3 checkc6nne"ii"""'iJi,'i!t I";l???rTr 8.20.2 Open flued appfiance the, main burner as uncter ,T:fy: 8.2.1.2. - y_1s_9r9*, screws ?d;;: . tle retaining 'orOer, .iJ# in reverse .l?^1.j9r91" using wasners, if necessarv. Check connections forgassoundness. ffilr 8.21 Change of pilot gas filter Removepilotgas linefrom the pilotgas filter by disconnectingthe union nut (G6). Unscrewthe pilotgas filterfrom the gas section. Reassemble in reverse order, using suitable sealingcompoundsparingly. Check connectionsfor gas soundness. 8.22 Change of automatic valve stuffing box Disconnectthe differentialvalve as under 8.6. Control lines remain connected.Unscrew the stuffing box (G7), taking care not to bend the oin. Reasemble in reverse order. usino new wasner. Check connectionsfor gas soundness. 8.23 Change of switch box lsolatethe appliancefrom the electricalmains. Markthe pilotlines,disconnectthe tubingnuts and remove oilot lines. Pull the thermocoupleout of the pilot burner assemblyand unscrewthe retainingunionnut (82) from the switch box. Remove the 2 retainingscrews (Bl) and pull out the switchbox. Notethe colourcodes of the wiring and pull the AMP plugs from the micro switches. Reassemblein reverseorder. Check - earth continuity - polarity - resistanceto earth accordingto INSTRUCTIONSFOR BRITISH GAS MULTIMETER. Checkconnections for gas soundness. 40 v ""0 3? 3 i:Hl""ls :g:ti ffi:t'ru1"1 'm#,lx;l*:w',?::#3 a bY rePrace and valve stuffing box 8.24 Change of FFD in reverseorder' Reassemble continuity earth Check - PSlflillset:f,S,l, ,o" BR,''H a"ft'$it'''-+?JU"JF'"*nn""'ionsforgassoundness' 6nJ"n L Fig.83 {, buttons 8.25Changeof FFDPush under8'23' asoutlined ""t""" "" t*itch box push pulloutthe and (ffi) io"r.ingr.ing llm; buttonto the tront' in reverseorder' Reassemble Check -- earth.continuity polarlry B3 "A b'ln-s+4"t3;'gKs FoRBRrrrsH """.rdi[ 6nsvuirtuEren' gassoundness' 6n""n "onn""tionsfor Fig.84 valve 8'26 Changeol Pilot (85) (84)andp9l!gut spring ofuq tn. Unscrew -€f b t ;:flJfl:iin[i'f,lst;'igslas':n?"1"J':: F 6io"t' utinga newwasher' gassoundness' Checxconiectionsfor l. Ynllli rtb 8.27 Change of thermo-magnet Removethe switch box as outlinedunder8.23. Removemicro-switchassemblyby unscrewing the 2 retaining screws (88). Skaighten tap washer (B9),unscrewretainingnut (B10),pull out thermo-magnet (B11) carefully. Reassemblein reverseorder. Check - earth continuity Polarity - resistance to earth accordingto INSTRUCTIONSFOR BRITISH GAS MULTIMETER. Check connectionsfor gas soundness. <G> .- 3 rig.e6 <88 8.28 To open the control box lsolatethe appliancefrom the electricalmains. Open the main terminal box by removingthe retainingscrew (C1).Remove the four retainingscrews (C2). Lift up the switch box and pull out slowly the control box cover complete with the switch board, printed circuit and terminal board. Pull off the multiple plugs from the printed circuit. Reassemblethe box in reverse order. When replacing the screws, position the 2 star washersdiagonallyto the screws. 8.29 Change of main swilch board Take off the switch board as outlined under 8.28. Disconnect the mains cable from the terminals.Unscrewthe 2 retainingscrews (C3) and removethe p.c.b.withthe mainswitchfrom the crontrolbox cover. Reassemblein reverseorder. Check - earth continuity - polarity - resistanceto earth accordingto INSTRUCTIONSFOR BRITISH GAS MULTIMETER, b ,z-4.t - "v4r( Fig.BB 42 8.30Changeof micro-switchesof water section Opencontrolboxas in 8.28andremoveswitch screw box as in 8.23.Removethe adjustment (C5) and take off the microswitchassembly. PulloffAMPplugs(C4). in reverseorder. Reassemble Check - earthcontinuity - PolaritY - resistancelo earth FOR BRITISH accordingto INSTRUCTIONS GASMULTIMETER. o 8.31Changeof overheatcut-off device Openthecontrolboxas in 8.28andremovethe switchboxas in 8.23. Pull off the 2 plugs(CG)and the earthlead, removethe saddleclip (C7),pull the sensor (3, fig. 52) out of the main heat exchanger. Unsciewthe 2 retainingscrews(C8),release grommetfromboxand removecut-offdevice. in reverseorder. Reassemble Check - earthcontinuity - Polarity - resistanceto earth FOR BRITISH accordingto INSTRUCTIONS GASMULTIMETER. forgassoundness. Checkconnections ) L rt 8.32Changeof electronic P'c.b' Openthe controlbox as outlinedunder8.28. Uirscrewthe retainingscrew (C9) on the left handsideof the controlbox.P.c.b.is heldon key-holeslot, pull p.c.b. forward and to the andwhitelead. right.Pulloff multiplug Reassemblein reverseorder and ensurethe p.c.b.is locatedon the lefthandsideof plastic peg. Check - earthcontinuity - polarity - resistanceto earth FOR BRITISH accordingto INSTRUCTIONS GASMULTIMETER. 8.33Ghangeof expansionvessel 8.33.1Domesticwater side Disconnectthe tubing nut (W1), unscrew bracketsecuringscrewandremoveexpansion vesselcompletewith bracket.Unscrewvessel from bracket.Reassemblewith new domestic waterexpansionvesselin reverseorder. 8.33.2Heatingsystem open flued appliances Disconnect the flue at splitcollar.Remove2 screwsand nuts,securingthe upperretaining frame.Lift rear of frame clear of side frames and rest it on top of draughtdiverter.Remove screwssecuringdraughtdiverterand remove togetherwith upperretainingframe.Remove draughtdiverterretainingframe by removing the 2 retainingscrews.Undothe union nut (W3),movetheexpansionvesselupandtakeit off. Reassemblein reverseorder,takingcare thatthe expansionvesselis correctlyfixedinto the2 supports. Usenewwasher,if necessary. 8.33.3Heatingsystem balancedflued appliance lsolateelectricalmains and removemains cable.Closeoff water and gas servicecocks anddraintheappliance as outlinedin 8.1.2. Disconnectflow and return connectionsat compressionjoints on top of service cock. Disconnectgas connectionat compression joint on top of gas cock.Disconnectdomestic hot and coldconnections on diaphragm body. Slacken locking nuts on flow and return connections.Removenuts from bolts (1 in fig. 14) on terminal/duct assemblyRerirove boilerfrom wall. Disconnect sleevenut (W3) and removeexpansionvessel.Reassemblein reverseorder,takingcare that the expansion vesselis correctlyfixedto the 2 supports. : 44 \_) 8.34 Change ol thermometer Pull the temperature sensor (U3) out of the sensor tube. Press the 2 tongues into the thermometerand pull it out to the front side' Reassemblein reverseorder. ) t 8.35 Change of manometer Disconnectthe tubing nut (U1) ot the control line and removethe fixing nut (U2). Reassemblein reverseorder. ffi\ v A w b t ^ 8.36Changeol systembYPass Close off flow and returnservicecocks and in 8.1.2' drainboileras outlined nuts (V) and remove 2 union the Unscrew valve.Unscrewthe3 screwsholdingthetopol the valve. Renew diaphragmor spring as Do not movespringadjustingnut' necessary. Reassemblein reverse order, using new wasners. S 9 Fault Finding 9.1 Sheet 1: Check of Flame Failure Device and Thermocouple b rsgas pressure available? Push green button and light Pilot. Can Pilot be lit? De-aeratePilot Gas Pipe by unscrewing Pilot Adlustmdnt Screw. ls Pilot Gas Pipe de-aerated? Checkor clean,if necessary, PilotGas FilterandPilotJet. CheckPilotflamecorrect size.CheckThermo' Tip isclean. Check Dositionedin flame. Recitify any fault. 46 button Releas€:green afterabout 10seconds. - DaesPitot Flame re-main \ z Adiustment ot PilotFlameand Themocouple Gheck Thermocouple Vohage (min. 15 mV DC). (Open circuit). Voltage satisfactory? i 9.2 Sheet 2: Check Electricity Supply IMPORTANT:The preliminaryElectricalSystemChecksas containedin the B.G.C.multimeterinstructionbook are the first electricalchecks lo be canied out during a fault findingprocedure.On completion of the service/faultfinding task which has requiredthe breaking and remakirtgof electricalconnectionsthen the checks - A. Earth Continuity,C. Polarityand D. Resistanceto Earth - must be repeated. PreliminaryElectlical System Checks accordingto Instructions for BritishGas Multimeter. Push Main Switch into posilion l. Replacefaulty Neon and refil Main Switch Cover. Replacefarlty P.C.B. with Main Switch. ReI. to note 1. 48 Cheek Operalingol HeatingSystem (Sheet3) Check Operationot DomesticHot Water System (Sheel 6) Check switch lor DomesticHot Water (She6t5) Note 1 : Detach the Jollowing parts oithe control box: - unscrew the cover of the terminal box - unscrew upper part ot control box (2 screws) and press it a little bit upwards - unscret/v knob of boiler thermostat - unscrew front panel ot control box with switch group - pull off multicontactplugs Aand B - remove printed circuit by loosening the two screws beside the switch group - install new orinted circuit 49 9.3. Sheet 3: Check Operation of Heating System (Do not use domestichot Water, switchfor domestichot water remainsin PositionZl) Can Pilot be Iit? Switch give . light? / Push HeatingSwitch into positionl. ' ls voltage \ 240 V AC trom ls Overheal CufOfi Device of OverheatCut-Off-Device @on P.CB tat'f 50 Overheat €*t :,t-Otf Device. eef. lo note 2. ls voltage 2ZIOVAC trom teminal Does Main Burner light? Are external Thermostats tested? Go to sheet 4 -:Eck contacts d Overheat :loff Device. a€i. to note 3. Fleplacefaulty Thermostat. Ret.to note5. Check that Multiplugs@ arid : ile clean, tight ild mrrectly :r:siti.cned. Ref. note 4. Check external Thermostalsaccorclino ' to lnstructionstor BritishGas Multimeter. Flepeatthe tollowing checks: A. Earth Continuity. C. Polarily. D. Besistanceto Earth accordingto Instructions for BritishGas Multimeter. Note 2: For re.s€tting, press the black rubber butlon on right hand side of control box behind the terminal box. Note 3: For this purpose, open the control box as describ€d in Note 1. The overheat cut-off device isiitt(i on right hand side ofthe control box- Checkitthe flat plugs ofthe overheat cut-otl device are tight. Nole 4: For this purpose, open the control box as described in Note 1 Pull off the multicontact plugs A and B and check that not contact lugs are bent. It necessary, readiust contact iugS and reset multicontact plugs again. Note 5: To check, disconnecf contrclsystemlrom terminals 3 and 4, and replace with wire loopto run boiler in heating mode. 51 9.4 Sheet 4: Check Electronic and Hydraulic System lsvoltage \ / 5tol5VDCatDC Check that MultiplugA connectionsare clean, tight and correctly positioned. ls MultiplugA tested? Pull otf connection of NTC probe. Ref. to note 7. ls NTC probe tested? Replacefaulty P.C.B. with Main Switch. Ref. to note 1. ls Micro Switchon FFD tested? Check grey connections on FFD Micro Switch lor 24OV AC from Terminal5 to connections.Replace Micro Switch if faulty. z ls voltage' tol5VDCat Solenoid?Ref. to Replacefaulty NTC probe. Check black connections on FFD Micro Switch clean, tight and correctly oositionedtor 5 to 15 V DC from brown connectionon DC solenoidto black FFD connections.Reolace Micro Switch if faulty Ret. to note 8. Re{itconnection to NTC probe. Hasfuseon Electronic P.C.B. Replace0.25 Amp. fuse. Replacetaulty ElectronicP.C.B. Ref. to note 9. 52 Check that wire is connectedto Terminal l, ll or lll. ReL to note 10 Nole 6: The D.C.-voltage of 5-15 V is controlled at the supply terminals of the solenoid vatue. Attention! When the indicator tums.to the left, the measuring lines must be reversed. On ignition ot the bumer there must be a D"C.-voltage ot 15 V. The voltaqe decroases flow io the according temperature until the electronic (at approx. 5. V D.C.-voltage) tums oft the solenoid valve (dead) the burner and extinguishes. Note 7: Thls test shows whether the NTc-sensor has an inner shorl circuit (resistance down at zero). For this purpose, pull the NTCsensor plug off when the (Jlow appliance is cool temperature less lhan 50'C). lf the electronic is satisfactory, the appliance must operate. Does Pumprun? DoesMaan Burnerlight? Are Pump Setting Terminals tested? Difterentral Valve tested? 240 V AC lrom termrnal 5tol. connectlons on FFD tested? Checkpumpaccordrng to lnstructionstor BritishGas Multimeters, Procedure9. ) .! Repeatthe following cnecKS: A. EarthContinuity. C. Polarity. D. Resistanceto Earth accordingto Instructtons for BritishGas Multimeter. ReplacefaultY DC Solenoid. Move Heating Switch ON-OFF-ON.Diaphragm pin on Difterential Valve has to move OUT-lN-OUT.If not, '1. Clean Venturi 2. CheckDiaphragm at differentialvalve and replace,jf necessary. Ref. to note 11. Attention! Pull otf the NTC-plug for a short time only because the normal temperalure control is out of functionin that position.In this case the applianceis only protectedby the overheatcutoff device. Note 8: For this purpose, open the control box as described in Note 1. Unscrew the pilot gas tubes of the thermoelectric casing and check it the black cables oJ the micro switch are tight. AfteMards installpilotgas tubes again Before re-assemblingthe control box. check the finewire tuse of the eleitronic. lf necessary. replace it' Attach plugs A and B again and re-assemble control box. 9: - For this purpose, open control box as described in f.fote f . Pull'off the multicontactplugs A and B The electronic-printed circuit can be removed .by unscrewind the cross-recessed head screw on the left hand siddof the control box. Pull out the printed iircuit towards the front and pull off the multicontact plug as well as the white cable. Note 1O: Attention: External llnes must not be connected to the terminalsl, ll and lll (shortcircuit!) The black cable can be connected to terminal l, ll or I ll ' It must be checked whether the black cable is connected tightlY enough Note11: lf the movement of the diaphragm pin cannot be checked optically. the pressure ditferential switch must be removbd by unscrewing the 3 screws Do not unscrew the two connection tubes! Under perfect function the diaphragm pin cannot be pushed back by hand, when pump oprates. lf lhis is, however, possible, the venturi tube' Pressure difierential iwitch, connectionstubes or pump, must be checked. Special attention must be given to the tact that the venturi O-ring ist nol damaged. Install the electronic-printed circuit in reverse order' RE t"9.5 Sheet5: GheckSwitch for DomesticHot Water (HeatingSwitchin position"O" do not usedomestichotWater) Can Pilot be lit? -Does Pilot lamp in Main Switchgive 1 light? - SetSwitchfor Domestic HotWater to positionI Go to sheet 2 Device(Ret. to note 2) and check connections n if no voltaqe240 V from lermin;l 5 to 4. Check Micro Switch M1 by drawing hot water. Micro Switch M1 has to be actuated(closed)bv Switch Lever.Observ6 piston rising!Adjustor Micro SwitchM 1 no voltage240 V AC from terminal4 to 5 Bel. to note 12 54 i - ls voltage 240VAClrom Does Main Bumer light? Repeatthe tollowing i checks: A. Earth Continuity C. Polarity. D. Resistanceto Earth accordingto lnstructions lor BritishGas Multimeter. NO Go to sheet 4 ls Overheat Cut-O'tf Device Switch M1 on llow switch tested? check that MultiplugA connstions ile clean, tight and corectly oositioned. "summei'is onlycontrolledby.themicroswitchM1ol theflowswitch' Note | 2: Thetunction iug mustoperatethe microswitch Duringdomestichot t"t"iiiii'JtioiiinJi6itlct Ml (close). is necessary' adiustment lfthe microswitchis notoperatedby the contactlug' an - switchotf oDeration (apglign-ce^9.t1!ot tap water warm For this Durpose,openthe sivitch)bv meansof a mainswitch).]lghten tnJiiri oi tne'iwititr'roit(topol flow frg:::Jlli:"":H LgftT#';lT'lJ$s'#"HlFr'IH!."* )li,j"i notiouin tn" casingof the microswitch' Note 13: See tigure 99 for micro switch Ml' 55 9.6 Sheet 6: Check Operation of Domestic Hot Water System (Heatingswitch in position0 switchfor domestichot water in positionZll Can Pilotbe lit? lamp in Main Switchgive 1 light?-z Go to sheet 1 Go to sheel 2 Heating \ Switchto l. Does . Main Burner Set Heatinq Switchlo "o-" and draw hot water Go to sheet 3 Note 14: For this purpose, open the control box as described in Note .l and remove front panel. Thus the micro swilch is accessible and the movement of the switch Dinof the water section can be observed. Ooen the warm water tap. With a water flow.quantity ol approx. 1 l/min. the switch pin must move and operate the micro switch via the switch lever which can be adiusted. lf the switch pin of the wdter section does not hove, the water section must be removed and checked (diaphragm). lf the micro switch does not operate despite the fact that the switch pin moves, the switch lever must be readiusted. For this, unscrewthe support ofthe micro switch and push itdownward until the switch lever contacts thetop oiwater section. Fix the suOport in this Dosition. 56 - lsvoltage \ 240 V AC from Does Main Burnet NO R€peatthe tollowing checlG: A. EarthContinurty. C. Polarity. D. Resistanceto Earth accordingto Instructions tor BritishGas Mullimeter. 4 lsWater Slection tested? Swkh off electricRy, t€move Control Box Cover. Ooen and close hot water iap. Diaphragm Din of waler seclion has to move up and down. Draw otf one l/min. and Pin has to be in upper positjon. lf not, clean Water Sedion according seruicing instructions. Ref. to note 14. Switch on eleeticity. - ' lsvoltage 240 V AC trom ls Micro Swildt acluated? Close Control Box. Adiust Swilch Lever by slac*ening screw in elongated hole. Bet. to Note 14. t Beplace Micro Switch. ls voltaoe\ 240VAC?om 57 VCW-sine 18 TgW vcw20/1T3w vcw2s/1T3w U6 IUIt(vl! lValllantl L-- OVERHEAT CUT-OFFDEVICE DIFE PRESSSWITCH HEATING (DOM.HOT WATER) SWITCH 412 br FLOWSWITCH A1 to A12 = M u l t i p l u gA 81 to 811 = M u l t i p l u gB E1 to E12 = Multiplug Electronic Single Plug on Electronic T 2 t o T s = Terminals bkl to bks= Black Wire with Marking Number 810 gv TIME FROST STAI CONTROL ANDTOR ROOMTHERMOSTAT NTC-RESISTOR Fig. 98 58 vEffi$iii#* M FLOW SWITCH NTC_RESISTOF OVERHEAT CUT-OFF \ DEVICE I z cc F o U J Fig.99 i o 59 Fig. 100 12 11 E 3 9 Fig.103 9 o Fig. 105 60 10 Short Part list Key No. Description 1 2 3 4 5 6 7 I 9 10 11 12 '13 '14 15 diaphragm washer diaphragm overheatcut-offdevice flowthermometer pressuregaugq switchboard screw support piezo-unit knob screw automaticairvent expansionvessel draughtdiverter 16 sidepanelrighthand VCW...20, VCW-sine 18 17 sidepanellefthand VCW...20, VCW-sine 18 18 frontpanel 19 centresection 20 door 21 22 23 support protec{ioncap burnercomplete 24 25 thermocouple knobcomplete 26 27 28 cover ductboltcomplete hightensionlead vcw...20 vcw...25 vcw...25 vcw...25 vcw...20,25 VCW-sine 18 vcw...20,25 VCW-sine 18 vcw...20.25 VCW-sine 18 VCW...20 NaturalGas VCW...25 NaturalGas green red PartNumber G.C. Number 01-0318 98-0151 02-0220 10-1363 10-1002 10-1008 13-0132 07-0334 08-6165 09-1008 14-3935 14-0012 06-1704 18-1001 07-3965 07-3966 07-1143 07-3730 07-1144 07-3729 07-1043 07-4161 07-1044 20-8619 07-1046 07-4008 15-4n5 07-2306 04-4563 o4-45U 17-1125 11-4208 11-4209 07-2313 094102 08-4432 262329 262335 262356 262494 263906 262907 262489 263986 263987 262488 263935 263950 262418 262419 262446 262427 262425 262426 262437 .263973 262439 263974 262433 263976 262416 262398 262382 262383 262402 262477 262478 262223 262216 262215 61 11 TechnicalData Type Nominalheatingcapacrty Nominalheatinginput (basedon gross C.V.) VCW 2 5 1T 13 W VCW 2011 T3W 24 (81e00) (86,4) VCW-sine18 T3W )64 (e0800) 31 (105800) ( 111 , 6 ) (1212OO) t1t7 A\ (66500) (7O,2) (BTU/h) (MJ/h) 26 (88700) (e3,6) (Bru/h) (MJ/h) Pilotburnerjetsize lorNG 34 34 40 Main burnerjetsize IorNG 14x7h30 16x7/130 12x1 125 numberx mark Burnersettingpressure 9 , 0( 3 , 6 1 ) 9 , 0( 3 , 6 1 ) 1 0 , 6( 4 , 2 6 ) mbar (in WG) Minimumwaterllowlor "C rise heating system 20 1000 (222\ 1250 900 (200) Vh ( l m p .G a l . / h ) gas Delivered (s.t.p.) GrossC.V. (s.r.c.) Gasconsumption G20 39,9(1070) 2,95(1,741 24 (1365) G20 s 9 , 9( 10 7 0 ) 3 , 3 8( 1, 9 9 ) G20 3 9 . 9( 1o 7 o ) 2 . 4 7( 1 , 4 5 ) MJ/m3(BTU/cu.ft) m3/h(c.f.m.) Nominal capacity for domesticwater 26,6 ( 15 13 ) A q Nominalcapacity(waterf low) ofdomesticwater 7,6 (1,67) (1,87) Water capacity ol heat exchanger 0,26 (0,057) 0,30 (0,066) 19,5 (1109) 6,2 (1,36) o,26 (0,057) Max. nominal flowtemperature (BTU/min) limin(45 K rise) ( l m p .G . / m .8 1 ' F r i s e I ( l m p .G a l . ) "c 90(1s4) Milimum total watercapacity of heating system (cold 1)) forsealedsystem fF) 260(57,2\ l ( l m p .G a l . ) 1 O( 1 4 2 J b a r( P . S . l . ) 0 , 1 5( 2 , 1 3 ) b a r( P . S . l . ) Minimumwater pressure for domestic water supplyof 1 l/min. o,2(2.84) b a r( P . S . l . ) Pump pressureavailablefor central heating system applianceas deliveredabout UPS 18-60 sparehead about 0,25 (8,4) 0,205 (6,9) Maximum water pressure Minimumstatic head for open heatingsystem 59 (130) Weigth Electric connection Voltage Input internalFuse externalFuse 60 (132) bar (feet) bar (feet) 68 (15ol 240/50 120 2 3 kg (pound) VlHz Amp (slow) Amp (slow) 1) For systems havinga largerwater capacityan additionalexpansionvessel can be installedeasily.Subjectto alteration. Headquariers Vaillant Ltd. VaillantHouse Medway City Estate Trident Close Rochester/Kent MEz 4 EZ ! mm (in.) 125 (5) Nominalsize oftlue pipe marKrng Central Region Office Vaillant Ltd. Unit 5 Providence lndustrial Estate Providence Street Lye, Stourbridge West Midlands DY 9 8 HO Tel.0634-712868(Sales) Te|.0384€91816(Sales) S e r v i c e ) T e | . 0 3 8 4 { 9 3 3 6 8( S e r u i c e ) T e | . 0 6 3 4 - 7 1 2 8 4( 4 0891b - Printedin Germany- lmprimden Allemagne Northern Region Otfice Vaillant Ltd. VaillantBuilding Euroway Estate Wharfedale Road Bradford West Yorkshire BD 4 6 SB ret.0274-688322 (Sales/Seruice) f,