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 GC29B Gas combi boiler SEDBUK TR05A153.B1107...
CONTENTS USER INSTRUCTIONS Boiler controls 1.1.1 Control panel layout 1.1.2 Operating the appliance 1.1.3 Operating modes 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, display and appliance operation...
Page 4
CONTENTS COMMISSIONING General warnings Filling the system Flushing the system Filling the condensate trap Starting the boiler Checking gas pressures 5.6.1 Working pressure (at meter and appliance) 5.6.2 Mechanical minimum gas pressure 5.6.3 Mechanical maximum gas pressure 5.6.4 Maximum and minimum CH gas pressures 5.6.5 Ignition sequence gas pressures Control parameters...
GENERAL INFORMATION 1 USER INSTRUCTIONS 1.1 Boiler controls 1.1.1 Control panel layout 1. ON/OFF button TIME 2. Central Heating Control knob 3. Hot Water Control knob DISPLAY button MODE SERVICE button ON / OFF MODE button 7. Mains supply terminal board 8.
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.
• 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 9
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. •...
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...
TECHNICAL CHARACTERISTCS 3 TECHNICAL CHARACTERISTICS 3.1 Technical data Model GC29B Appliance Type C12 C32 C42 C52 C82 Appliance Category II2H3+ Heat Input max Heat Input min Heat Output max (50/30°) 30.87 Heat Output max - 80/60° C (Non-condensing) 29.01 Heat Output min - 80/60° C (Non-condensing) 16.87...
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 TR05A153.B1107...
TECHNICAL CHARACTERISTCS 3.6 Control panel, display and appliance operation 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.
TECHNICAL CHARACTERISTCS 3.6.3 Operating modes Heating Only Mode Hot Water Only Mode & Heating & Hot Water Mode 3.6.4 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.
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;...
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. ■...
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.
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 and DHW pipes must be adequately earthed.
INSTALLATION INSTRUCTIONS 4.4.2 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.
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.
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.
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.
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.
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 .
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.
INSTALLATION INSTRUCTIONS 4.8.2 Horizontal coaxial balanced flue – Ø 60/100 (Kit K) FOR CONDENSING BOILERS ONLY Ø60/100 MAXIMUM FLUE LENGTH = 4 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).
INSTALLATION INSTRUCTIONS 4.8.3 Horizontal coaxial balanced flue – Ø 80/125 FOR CONDENSING BOILERS ONLY Ø80/125 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).
INSTALLATION INSTRUCTIONS 4.8.4 Vertical coaxial balanced flue – Ø 60/100 (Kit V) FOR CONDENSING BOILERS ONLY Ø60/100 MAXIMUM FLUE LENGTH = 4 m * The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below).
INSTALLATION INSTRUCTIONS 4.8.5 Vertical coaxial balanced flue – Ø 80/125 FOR CONDENSING BOILERS ONLY Ø80/125 MAXIMUM FLUE LENGTH = 5 m * The total length is calculated by summing the lengths of all the straight section AND the equivalent lengths of each bend (see below).
INSTALLATION INSTRUCTIONS 4.8.6 Flue diaphragm installation – Coaxial balanced flues The adjustable flue diaphragms MUST ONLY be installed on the top of the boiler. They MUST NOT be installed elsewhere in the flue system. Installation Instructions (see Figure 26): Clean the surface of the boiler flue spigot; −...
INSTALLATION INSTRUCTIONS 4.8.7 Flue diaphragm adjustment – Ø 60/100 Coaxial balanced flues NUMBERS FOR ADJUSTMENT INDICATOR TOTAL EQUIVALENT DIAPHRAGM FLUE LENGTH SETTING from 0 to 1 m Remove tags from both discs from 1 to 4 m Do not fit either disc MAXIMUM FLUE LENGTH UPPER DISC...
INSTALLATION INSTRUCTIONS 4.8.9 Twin Pipe flue system – Ø 80/80 (Kit H) FOR CONDENSING BOILERS ONLY Ø80/80 MAXIMUM FLUE LENGTH = 40 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...
INSTALLATION INSTRUCTIONS 4.8.10 Flue diaphragm installation – Twin pipe flues The adjustable flue diaphragms MUST ONLY be installed on the top of the boiler. They MUST NOT be installed elsewhere in the flue system. The adjustable flue diaphragms of a twin pipe system MUST be installed on the AIR INTAKE. Installation Instructions (see Figure 31): Remove the air intake cover;...
INSTALLATION INSTRUCTIONS 4.8.11 Flue diaphragm adjustment – Ø 80/80 Twin pipe flues NUMBERS FOR ADJUSTMENT INDICATOR TOTAL EQUIVALENT DIAPHRAGM FLUE LENGTH SETTING 10 m from including inlet & exhaust sections 30 m from including inlet & exhaust sections 40 m from Do not fit either disc including inlet &...
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.
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 4.4.3). AIR VENT VALVE PLUG PUMP Check the properties of the water supply and install the appropriate treatment devices if the mains water has a...
COMMISSIONING INSTRUCTIONS 5.4 Filling the condensate trap The condensation trap MUST be pre-filled when starting the boiler for the first time in order to prevent flue gases from escaping via the drain. The filling operation is carried out as follows (see Figure 35): Remove plug T and fill the trap S three quarters full with water;...
COMMISSIONING INSTRUCTIONS 5.6 Checking gas pressures 5.6.1 Working pressure (at meter and appliance) The working pressure at the meter should be checked to confirm that it corresponds to the value stated on the meter regulator. The appliance inlet working pressure should be checked to confirm that it corresponds to the value stated on the boiler data plate and in Section 5.8, and also that there is no excessive pressure loss in the supply pipe work.
COMMISSIONING INSTRUCTIONS When the pressure has been checked: • Switch off the appliance and close the gas supply isolation valve; • Disconnect the pressure gauge then reopen the isolation valve. If the measured pressure does not equal that stated on data plate, or if it is more than 1 mbar less than the working pressure at the meter, check the gas supply pipe work.
COMMISSIONING INSTRUCTIONS Once the boiler has been successfully fired (to eliminate all air from the gas supply line): • Access the Control Parameters Menu following the instructions in Section 5.7.1; • Access Parameter 11, following the instructions in Section 5.7.2, at which point the boiler will fire; •...
COMMISSIONING INSTRUCTIONS 5.7 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.
COMMISSIONING INSTRUCTIONS 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 & buttons. Step 3: Press and hold the button.
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 47
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 48
COMMISSIONING INSTRUCTIONS Parameter 7 – CH pump overrun timer Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = 0 x 5 seconds = 0 seconds (minimum) 90 = 90 x 5 seconds = 450 seconds (maximum) Note: Factory preset to 36 = 180 seconds Press and release the button.
Page 49
COMMISSIONING INSTRUCTIONS Parameter 10 – Minimum gas pressure (in CH mode) Refer to Section 5.6. Access the parameters menu as described in Section 5.7.1. Use the & buttons to adjust the parameter value: 00 = Gas valve at mechanical minimum gas pressure 50 = Gas valve 50% open (maximum) Note: Factory preset to 20 = Gas valve 20% open Press and release the...
COMMISSIONING INSTRUCTIONS 5.8 Gas data 5.8.1 Technical reference tables Gas Type Minimum Gas Pressure / mbar Maximum Gas Pressure / mbar Natural Gas (Methane) – G20 LPG (Butane) – G30 26.6 LPG (Propane) – G31 10.9 32.4 Table 6: Reference fan speeds Natural Gas Liquid Butane Gas Liquid Propane Gas...
COMMISSIONING INSTRUCTIONS 5.9 Converting to a different gas type Figure 39: Gas type convertion The conversion of a boiler from burning natural gas to LEGEND : LPG, or vice versa, must only be carried out by GAS VALVE professionally qualified personnel registered STABILISER...
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.
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 •...
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 3.6 for how to operate the appliance; Isolate electricity and •...
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.
MAINTENANCE INSTRUCTIONS 6.7.1 Primary heat exchanger and burner unit • Isolate the electricity, water and gas supplies to the appliance; • Remove the casing panels (see Section 6.3); • Remove the fixing screws of the combustion camber front panel and pull the panel outwards; •...
MAINTENANCE INSTRUCTIONS 6.7.2 DHW heat exchanger • Isolate the electricity, water and gas supplies to the appliance; • Drain the domestic hot water circuit and central heating circuit of the boiler (see Sections 6.4 & 6.6); • Use a 4 mm Allen key to unscrew the two screws securing the heat exchanger to the manifold;...
MAINTENANCE INSTRUCTIONS 6.7.4 Safety thermostat • Isolate the electricity, water and gas Heating Safety supplies to the appliance; sensor thermostat • Disconnect the connecting wire; • Unscrew the fixing screws and remove the thermostat; • Replace the thermostat and re-assemble components following above...
MAINTENANCE INSTRUCTIONS 6.7.7 Electric fan • Isolate the electricity, water and gas supplies to the appliance; • Disconnect the fan electrical connections • Remove the fan bracket fixing screws; • Take hold of the fan body and shift it to the right, then pull it forwards and out of its mounting;...
MAINTENANCE INSTRUCTIONS 6.7.9 Circulating pump motor body • Isolate the electricity, water and gas supplies to the appliance; • Drain the central heating circuit of the boiler (see Section 6.4); Pump impeller body Pump motor body • Use a 5 mm Allen key to unscrew the four screws securing the motor body to the impeller body;...
MAINTENANCE INSTRUCTIONS 6.7.11 Printed circuit board (PCB) • Isolate the electricity, water and gas supplies to the appliance; Printed circuit board (PCB) • 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 PCB;...
MAINTENANCE INSTRUCTIONS 6.7.12 Secondary heat exchanger • Isolate the electricity, water and gas supplies to the appliance; Support bracket • Drain the central heating circuit of the screws boiler (see Section 6.4); • Remove the fixing spring clips and then Secondary heat the flow, return and condensate drain exchanger...
MAINTENANCE INSTRUCTIONS 6.9 Troubleshooting 6.9.1 Error codes CODE PROBLEM POSSIBLE CAUSE REMEDY IF BOILER FAILS TO FIRE NO GAS CHECK MAINS SUPPLY GAS INLET PRESSURE TOO HIGH CHECK INLET PRESSURE MECHANICAL MINIMUM OR IGNITION SEQUENCE CHECK AND ADJUST MECHANICAL GAS PRESSURES TOO LOW MINIMUM AND IGNITION NO FLAME SEQUENCE SETTINGS...
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:...
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...
OPTIONAL CONTROLS 7.2 Weather compensating controls An Outside Sensor is available for use with this appliance and is strongly recommended in order to maximise appliance efficiency and user comfort. The sensor is easy to wire, connecting directly to the Se terminals of the mains supply terminal board. The control system carefully modulates the central heating flow temperature in accordance with the outside temperature as measured by the sensor.
Page 72
THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK...
Page 73
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 74
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 75
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...
Page 76
THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK...
Page 77
THIS PAGE IS INTENTIONALLY BLANK THIS PAGE IS INTENTIONALLY BLANK...
Page 78
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 THE TECHNICAL DATA AND MEASUREMENTS ARE PROVIDED FOR INFORMATION PURPOSES ONLY AND ARE NOT BINDING.