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Summary of Contents for WarmFlow GS25A
- Page 1 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 TR05A140.B1107...
- Page 2 TR05A140.B1107...
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Page 3: Table Of Contents
CONTENTS USER INSTRUCTIONS Boiler controls 1.1.1 Control panel layout 1.1.2 Operating the appliance Topping up the system (Error Code H20) If you smell gas GENERAL INFORMATION General warnings Information Product conformity TECHNICAL CHARACTERISTICS Technical data Dimensions Internal components Function diagram Circulation pump performance curves Control panel and display 3.6.1... - Page 4 CONTENTS Control parameter adjustment 5.7.1 Accessing the parameters menu 5.7.2 Adjusting the parameters Gas data 5.8.1 Technical reference tables MAINTENANCE General warnings Boiler inspection Accessing the boiler 6.3.1 Front panel removal 6.3.2 Side panel removal 6.3.3 Control panel access Draining the central heating system Flushing the central heating system Maintenance operations 6.6.1...
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Page 5: User Instructions
GENERAL INFORMATION 1 USER INSTRUCTIONS 1.1 Boiler controls 1.1.1 Control panel layout 1. ON/OFF button 2. Central Heating Control knob button button button ON / OFF 6. Mains supply terminal board 7. Digital LCD display 3 4 5 8. Programmer location (N/A) Figure 1: Control Panel 1.1.2 Operating the appliance Operation... -
Page 6: Topping Up The System (Error Code H20)
GENERAL INFORMATION 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 is bled from a radiator or if a radiator is replaced. -
Page 7: General Information
• In the case of a fault and/or malfunction in the appliance, shut down the system. Do not interfere with or attempt to repair the appliance. Contact your commissioning engineer in the first instance or contact the Warmflow Customer Care Centre on 028 9262 1515. - Page 8 GENERAL INFORMATION • 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. •...
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Page 9: Product Conformity
GENERAL INFORMATION 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 the... -
Page 10: Technical Characteristics
TECHNICAL CHARACTERISTCS 3 TECHNICAL CHARACTERISTICS 3.1 Technical data Model GS25A Appliance Type C13, C33, C43, C53, C63, C83 Appliance Category II2H3+ Heat Input max Heat Input min Heat Output max (50/30°) 26.67 Efficiency 100% (full load 50/30° ) 106.7 Efficiency 30% (partial load 50/30°) 106.3... -
Page 11: Dimensions
TECHNICAL CHARACTERISTCS 3.2 Dimensions 48.5 48.5 111.5 111.5 ON / OFF LEGEND HEATING RETURN 22mm HEATING FLOW 22mm 22mm CONDENSATE DRAIN 25mm Figure 2: Dimensions TR05A140.B1107... -
Page 12: Internal Components
TECHNICAL CHARACTERISTCS 3.3 Internal components Figure 3: Internal components LEGEND PRIMARY CONDENSING HEAT EXCHANGER PREMIX BURNER UNIT (GAS MANIFOLD + BURNER) HEAT EXCHANGER CONDENSATE DRAIN CONNECTION IONISATION ELECTRODE IGNITION ELECTRODE VENTURI IGNITION TRANSFORMER ELECTRONIC GAS VALVE 10. 3 BAR PRESSURE RELIEF VALVE – HEATING CIRCUIT 11. -
Page 13: Function Diagram
TECHNICAL CHARACTERISTCS 3.4 Function diagram LEGEND PRIMARY CONDENSING HEAT EXCHANGER PREMIX BURNER UNIT (GAS MANIFOLD & BURNER) HEAT EXCHANGER CONDENSATE DRAIN PIPE IONISATION ELECTRODE IGNITION ELECTRODE VENTURI IGNITION TRANSFORMER ELECTRONIC GAS VALVE 10. 3 BAR PRESSURE RELIEF VALVE - HEATING CIRCUIT 11. -
Page 14: Circulation Pump Performance Curves
TECHNICAL CHARACTERISTCS 3.5 Circulation pump performance curves 1200 1400 1600 1000 Flow l/h Available head at maximum speed Available head at second speed Available head at minimum speed Appliance Loss Figure 5: Pump performance curves TR05A140.B1107... -
Page 15: Control Panel And Display
TECHNICAL CHARACTERISTCS 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 protection. On first connection to the power supply, the appliance must be switched on using the ON/OFF button on the control panel to activate all of the above protective features. -
Page 16: Function Codes
TECHNICAL CHARACTERISTCS 3.6.3 Function codes Code Function Description Operates the boiler at maximum CH output for 15 minutes without modulation. Commissioning Mode Activated by pressing and holding the button for 7 seconds. Deactivated by switching the appliance off. Operates the boiler at minimum CH output in Heating Only Mode. -
Page 17: Installation
INSTALLATION INSTRUCTIONS 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 carried out in accordance with the relevant requirements of the: Gas Safety Regulations;... -
Page 18: Unpacking
INSTALLATION INSTRUCTIONS 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 damage caused by incorrect storage of the product. ■... -
Page 19: Installing The Boiler
INSTALLATION INSTRUCTIONS 4.3 Installing the boiler appliance must only ■ 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. -
Page 20: Water Connections
INSTALLATION INSTRUCTIONS 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 earthed. -
Page 21: Central Heating Circuit
INSTALLATION INSTRUCTIONS 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 system, the pump head, expansion vessel size, mean radiator temperature, etc. -
Page 22: Condensate Drain
INSTALLATION INSTRUCTIONS 4.5 Condensate drain Failure to install the condensate discharge pipe work Termination to an internal soil and vent pipe correctly will affect the reliable operation of the boiler. Boiler The condensate discharge pipe must not rise at any point along its length. -
Page 23: Gas Connection
INSTALLATION INSTRUCTIONS 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 of hemp, PTFE tape and similar materials is not allowed. -
Page 24: Electrical Connections
INSTALLATION INSTRUCTIONS 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 effective earth system. This requirement is only satisfied if it has been properly connected to an effective earth system installed in accordance with the requirements of current safety standards. -
Page 25: Power Supply
INSTALLATION INSTRUCTIONS 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. -
Page 26: Flue Connections
INSTALLATION INSTRUCTIONS 4.8 Flue connections In order to ensure that the appliance functions correctly efficiently, only Warmflow-approved flue components may be used with this appliance. Traditional flue components cannot be used for conveying exhaust fumes from condensing boilers. Coaxial Balanced Flues 0 . -
Page 27: Flue Position
INSTALLATION INSTRUCTIONS 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 free passage of air across it at all times. If the terminal discharges into a pathway or passageway check that combustion products will not cause nuisance and that the terminal will not obstruct the passageway. -
Page 28: Horizontal Coaxial Balanced Flue - Ø 60/100 (Kit K)
INSTALLATION INSTRUCTIONS 4.8.2 Horizontal coaxial balanced flue – Ø 60/100 (Kit K) FOR CONDENSING BOILERS ONLY Ø 60/100 MAXIMUM FLUE LENGTH = 5 m * The flue length is the total length of the flue excluding the first bend. The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below). -
Page 29: Horizontal Coaxial Balanced Flue - Ø 80/125
INSTALLATION INSTRUCTIONS 4.8.3 Horizontal coaxial balanced flue – Ø 80/125 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 bend. The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below). -
Page 30: Vertical Coaxial Balanced Flue - Ø 60/100 (Kit V)
INSTALLATION INSTRUCTIONS 4.8.4 Vertical coaxial balanced flue – Ø 60/100 (Kit V) FOR CONDENSING BOILERS ONLY Ø 60/100 MAXIMUM FLUE LENGTH = 5 m * The flue length is the total length of the flue excluding the first bend. The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below). -
Page 31: Vertical Coaxial Balanced Flue - Ø 80/125
INSTALLATION INSTRUCTIONS 4.8.5 Vertical coaxial balanced flue – Ø 80/125 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 bend. The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below). -
Page 32: Twin Pipe Flue System - Ø 80/80 (Kit H)
INSTALLATION INSTRUCTIONS 4.8.6 Twin pipe flue system – Ø 80/80 (Kit H) 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 sections excluding the first bend of each. The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see... -
Page 33: Commissioning
COMMISSIONING INSTRUCTIONS 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 factory pre-set and tested for burning Natural Gas (Methane). Nevertheless, when starting the boiler for the first time, make sure that the information on the rating plate corresponds to the type of gas being supplied to the boiler. -
Page 34: Filling The System
COMMISSIONING INSTRUCTIONS 5.2 Filling the system Use only a WRAS approved filling loop for connection and filling of the primary AIR VENT VALVE system. This should be disconnected when not in use (see Section 4.4.2). AIR VENT VALVE PLUG PUMP Check the properties of the water supply and use appropriate treatment agents if the mains water has a hardness rating... -
Page 35: Flushing The System
COMMISSIONING INSTRUCTIONS 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 corrosion inhibitors and softening agents must be added. -
Page 36: Starting The Boiler
COMMISSIONING INSTRUCTIONS 5.5 Starting the boiler Once the system has been flushed and filled, Gas Type Concentration / % proceed as follows: Natural Gas (Methane) – G 20 • Check that the exhaust flue is free of LPG (Butane) – G 30 10.9 obstructions and correctly connected to the boiler;... -
Page 37: Control Parameters
COMMISSIONING INSTRUCTIONS 5.6 Control parameters PARAMETER PARAMETER PARAMETER NAME FUNCTION NUMBER VALUE Non-storage boiler Boiler type Storage boiler (type 1) Storage boiler (type 2) Natural gas Fuel type Standard (30-80° C) for radiators CH flow temperature Reduced (25-40° C) for under floor Runs when controls call for heat. -
Page 38: Control Parameter Adjustment
COMMISSIONING INSTRUCTIONS 5.7 Control parameter adjustment 5.7.1 Accessing the parameters menu Step 1: Switch the appliance off using the ON/OFF button. O FF Step 2: Press and hold both the & buttons. Switch the appliance on using the ON/OFF button. Release the &... -
Page 39: Adjusting The Parameters
COMMISSIONING INSTRUCTIONS 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 and release the button. - Page 40 COMMISSIONING INSTRUCTIONS 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 button.
- Page 41 COMMISSIONING INSTRUCTIONS 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 –...
- Page 42 COMMISSIONING INSTRUCTIONS 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 the button.
- Page 43 COMMISSIONING INSTRUCTIONS Parameter 21 – Ignition sequence fan speed Access the parameters menu as described in Section 5.7.1. 1 1 0 Use the & buttons to adjust the parameter value: Minimum value determined by Parameter 17 Maximum value determined by Parameter 18 Note: Factory preset to 110 = 110 Hz Press and release the button.
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Page 44: Gas Data
COMMISSIONING INSTRUCTIONS 5.8 Gas data 5.8.1 Technical reference tables Gas Type Concentration / % Natural Gas (Methane) – G20 LPG (Butane) – G30 10.9 LPG (Propane) – G31 11.0 Table 7: Reference Carbon Dioxide concentrations Gas Type Minimum Fan Speed / Hz Maximum Fan Speed / Hz Natural Gas (Methane) –... -
Page 45: Maintenance
MAINTENANCE INSTRUCTIONS 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 the long life of the appliance, and in accordance with the current gas safety regulations, only use original spare parts. -
Page 46: Accessing The Boiler
MAINTENANCE INSTRUCTIONS 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 •... -
Page 47: Draining The Central Heating System
MAINTENANCE INSTRUCTIONS 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 supplies to the •... -
Page 48: 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 non-compliance with this instruction. -
Page 49: Primary Heat Exchanger And Burner Unit
MAINTENANCE INSTRUCTIONS 6.6.1 Primary heat exchanger and burner unit • Isolate the electricity, water and gas supplies to the appliance; Primary heat exchanger • Disconnect the electrical connections of the electric fan; Premix burner unit • Disconnect and remove the pipe linking the gas valve to the venturi;... -
Page 50: Ignition And Ionisation Electrodes
MAINTENANCE INSTRUCTIONS 6.6.2 Ignition and ionisation electrodes • Isolate the electricity, water and gas supplies to the appliance; Ionisation • Unplug the electrode wires; electrode • Slacken the fixing screws; • Remove electrodes. When refitting electrodes, check that the seals are not damaged and replace if necessary;... -
Page 51: Gas Valve
MAINTENANCE INSTRUCTIONS 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;... -
Page 52: Electric Fan
MAINTENANCE INSTRUCTIONS 6.6.7 Electric fan • Isolate the electricity, water and gas supplies to the appliance; Venturi • 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 remove the electric fan, noting the positions of the washer and diaphragm (see Figure 45);... -
Page 53: Modulation Circuit Board
MAINTENANCE INSTRUCTIONS 6.6.9 Modulation circuit board • Isolate the electricity, water and gas supplies to the Modulation circuit board 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 and remove the modulation circuit board;... -
Page 54: Wiring Diagram
MAINTENANCE INSTRUCTIONS 6.7 Wiring diagram PRINTED CIRCUIT BOARD KOND DT - SK11003 COD. 18767002 PRINTED CIRCUIT BOARD DIGITECH - SM20019 COD. 16766077 EXHAUST FAN type RG128/1300-3612 POWER SUPPLY Main Switch Air Pressure switch Safety thermostat Thermofuse 102° C fusibile 2A brown Heating sensor light-blue... -
Page 55: Troubleshooting
MAINTENANCE INSTRUCTIONS 6.8 Troubleshooting 6.8.1 Error codes CODE PROBLEM POSSIBLE CAUSE REMEDY IF BOILER FAILS TO FIRE CHECK MAINS SUPPLY NO GAS CHECK INLET PRESSURE GAS INLET PRESSURE TOO HIGH CHECK AND ADJUST MECHANICAL MECHANICAL MINIMUM OR IGNITION SEQUENCE GAS PRESSURES TOO LOW MINIMUM AND IGNITION NO FLAME SEQUENCE SETTINGS... -
Page 56: Parts Lists
MAINTENANCE INSTRUCTIONS 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 - PX2030 28432074 WASHER/OR CLIPS KIT FOR MULTIPLEX 28590015 WATER PRESSURE SWITCH PC 5411 BRASS 40735016... -
Page 57: Optional Controls
OPTIONAL CONTROLS 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 could be SEVERELY DAMAGED! 7.1.1 Appliance connections To fit a programmer, room thermostat or other external controls:... -
Page 58: S-Plan Wiring Schematic
Heating Zone Hot Water Cylinder Room Cylinder Thermostat Thermostat Permanent Live Add more valves & programmers Neutral Boiler as required Terminal Block 2-port zone valves Zone valve microswitches Zero-volt Switching Circuit... - Page 59 THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK...
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- Page 61 INSTALLATION, COMMISSIONING & SERVICING RECORD 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 Address CORGI Registration No. CORGI ID Serial No. APPLIANCE &...
- Page 62 INSTALLATION, COMMISSIONING & SERVICING RECORD COMMISSIONING PROCEDURE INFORMATION For All Boilers Has the system been flushed in accordance with the boiler manufacturer’s instructions? What cleanser was used? Has an inhibitor been added? Which inhibitor was used? For central heating mode, measure and record: Heat Input Burner Operating Pressure mbar...
- Page 63 INSTALLATION, COMMISSIONING & SERVICING RECORD Service 1 Service 2 Date: 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 Service 4 Date: Date: Engineer Name Engineer Name...
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- Page 66 WARMFLOW Engineering Company Limited Lissue Industrial Estate, Moira Road, Lisburn BT28 2RF Tel: 028 9262 1515 Fax: 028 9262 0869 Warmflow Customer Care Centre 028 9262 1515 048 9262 1515 Email service@warmflow.co.uk TECHNICAL DATA MEASUREMENTS PROVIDED INFORMATION PURPOSES ONLY AND ARE NOT BINDING. THE COMPANY RESERVES THE RIGHT TO APPLY VARIATIONS WITHOUT PRIOR NOTIFICATION.
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