andrews 24/39 Installation And Service Manual
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andrews 24/39 Installation And Service Manual

Standard and hiflo ranges - gas fired storage water heaters for natural gas, lpg/butane
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  • Page 2 UK users is drawn to their responsibilities under the Health and Safety Regulations 1993. All installation and service on Andrews Water Heaters must be carried out by properly qualified personnel and, therefore, no liability can be accepted for any damage or malfunction caused as a result of intervention by unauthorised personnel.

  • Page 3: Table Of Contents

    Contents Contents General and safety information General information British standards and codes of practice 1.2.1 Standard range & Hiflo range Health and safety regulations 1993 Effectiveness in combating legionella Technical data Standard range (Natural Gas) Standard range (LPG) Hiflo range (Natural Gas) Hiflo range (LPG) ErP data Installation...
  • Page 4 Contents Operation Standard range Hiflo range 5.2.1 Permanent pilot models, operating sequence HIflo and standard range auto ignition 5.3.1 Auto ignition units, operating sequence. Hiflo and standard range 5.3.2 ECO (energy cut - off) 5.3.3 Temperature stratification (stacking) Servicing Introduction 6.1.1 Servicing must be carried out by a properly qualified person Pre - service options...
  • Page 5 Contents 10 Appendix 10.1 Hiflo auto ignition “G” series addendum 10.1.1 Features of honeywell integrated control system 10.2 Specifications 10.3 Sequence of operations 10.4 Troubleshooting 10.4.1 Using control display for servicing the water heater 10.4.2 Service mode 10.4.3 To change the maximum setpoint limit (max setpoint) for the temperature setpoint 10.4.4 Display of water temperature...

  • Page 6: General And Safety Information

    General and Safety Information General and safety information General information The Andrews Water Heater has been designed for use with NATURAL GAS only and is manufactured to give an efficient, reliable and long service life. To ensure the continued, trouble-free operation of your heater at...
  • Page 7 General and Safety Information BS EN 806 (Parts 1 - 5) Specifications for installations inside buildings conveying water for human consumption. BS 6644 Installation of gas fired water boilers of rated inputs between 70kW and 1.8MW. BS EN 12897 Water supply. Specification for indirectly heated unvented (closed) storage water heaters.

  • Page 8: Health And Safety Regulations 1993

    Andrews Water Heaters should only be used in the manner and purpose for which they were intended and in accordance with the instructions in this manual. Although the heaters have been...

  • Page 9: Technical Data

    Technical Data Technical data Standard Range (Natural Gas) Andrews Model No. 24/39 32/40 40/61 63/62 84/87 Storage Capacity Recovery thro’ 50°C Recovery thro’ 56°C Heat Input Gross 12.5 Heat Input Net 11.4 NATURAL CAT I Burner Gas Pressure mbar Max. Gas Input Pressure...

  • Page 10: Standard Range (Lpg)

    Technical Data Standard Range (LPG) Andrews Model No. L24/31 L32/35 L40/36 L63/71 L84/74 Storage Capacity Recovery thro’ 50°C Recovery thro’ 56°C Heat Input Gross 11.0 11.0 22.0 22.0 Heat Input Net LPG CAT I Inlet Gas Pressure Propane mbar Inlet Gas Pressure Butane...

  • Page 11: Hiflo Range (Natural Gas)

    Technical Data HIflo Range (Natural Gas) Andrews Model No. 32/143 65/173 81/264 62/341 54/418 54/440 Storage Capacity 295* 368* 282* 245* Recovery thro’ 50°C 1053 1359 1668 1745 Recovery thro’ 56°C 1214 1489 1558 Recovery thro’ 72°C 1188 1212 Heat Input Gross 42.8...

  • Page 12: Hiflo Range (Lpg)

    Technical Data HIflo Range (LPG) Andrews Model No. L32/143 L65/169 L81/251 L62/309 L54/399 Storage Capacity Recovery thro’ 44°C 1140 1403 1812 Recovery thro’ 56°C 1122 1449 Recovery thro’ 72°C 1117 Heat Input Gross 41.8 92.5 Heat Input Net LPG CAT I...

  • Page 13: Erp Data

    Technical Data ErP data Standard Range Permanent Pilot 24/39 32/40 40/61 63/62 84/87 Declared load profile Water heating energy efficiency class Water heating energy efficiency Annual energy consumption Annual energy consumption Other load profiles for which the water heater is suitable to use and the corresponding...
  • Page 14 Technical Data Standard Range Natural Gas Permanent Pilot 24/39 32/40 40/61 63/62 84/87 Daily electricity consumption 0.001 0.001 0.001 0.001 0.001 elec Declared load profile Sound power level, indoors Daily fuel consumption 12.460 18.271 19.183 26.628 24.092 fuel Emissions of nitrogen oxides...

  • Page 15: Installation

    Installation Installation Introduction 3.1.1 The law requires that installation is carried out by a properly qualified person Installations must be carried out in accordance with Gas safety (Installation and Use) Regulations 1998, Building Regulations, The Water Supply (Water Fittings) Regulations 1999 and any requirements of the local Gas Authority, Local Authority, Water and Fire Authorities and the current British Standards and Codes of Practice.

  • Page 16: Location

    Clearances at the sides and rear of the heater should be at least 305mm. Above service clearances for removal of the anodes and flue baffles should be provided as detailed below. Standard Range Models 24/39, 32/40, 40/61 762mm Model 63/62 1143mm Model 84/87...

  • Page 17: Gas Supply

    Installation Gas supply Note The Andrews Water Heaters Covered in this Manual Must Only be Used with Natural Gas. The installation of the gas supply must conform, depending on it's size, to the requirements of British Standards and Codes of Practice.

  • Page 18: Electrical Supply - Auto Ignition Units

    This will eliminate the risk of possible interference from nearby high voltage cables. Data sheets available for Hiflo and Standard Range, Automatic Ignition Control System. Contact Andrews Water Heaters. Issue 2 14/07/16...
  • Page 19 Installation Fig. 3a Standard Range H.T Lead EARTH BINDING POST Maclaren Gas Block Relay 2 Gas to Main Burner ”BSP Volt Free Output For Over - Heat Red Cable Volt Free Output For Lock - Out Yellow Cable Relay 1 Interlock Contact 2 (Time-switch) Blue Cable...

  • Page 20: Flue Systems

    *A minimum of 600mm of vertical flue directly above the draught diverter should be provided where possible on all natural draught flue installations. If this dimension cannot be achieved please contact Andrews Water Heaters. Note 1. This flue run 2 & 3 are recommended flue runs...
  • Page 21 Installation Fig 5. Fig. 5 Common flues may be used on multiple installations only if all Each unit has an the heaters are of the same burner system and fuel type and atmospheric should be sized to ensure complete evacuation of the flue burner system &...

  • Page 22: Air Supply And Ventilation

    Installation Air supply and ventilation For all installations, please refer to the table below for calculating requirements. Detailed recommendations for the air supply are given in BS 5440 Part 2, BS 6644 Clause 19 and IGE/UP/10 Pt.1. Note The following notes are provided for general guidance only.
  • Page 23 Installation The minimum effective areas of the permanent air vents required in the compartment are as follows;-. Air Vent Areas Position of Air Vents Air from room or internal space Air direct from outside High Level 10cm per kW net per kW net Low Level 20cm...

  • Page 24: Water Quality And Treatment

    An additional Correx BEMS version is available, which provides a remote warning signal. These anodes are available as an optional extra on all Andrews heaters. In hard water areas, scale formation can occur in hot water...
  • Page 25 Installation WARD (Saffron Walden) Unit 3 Concord Farm School Road Rayne Essex CM77 6SP Tel: 01376 559670 Fax: 01376 340004 SENTINEL PERFORMANCE SOLUTIONS LTD 7650 Daresbury Park Daresbury Warrington Cheshire WA4 4BS Tel: 01928 704330 Fax: 01928 562070 www.sentinelproducts.com HYDROTEC UK LTD Hydrotec House 5 Manor Courtyard Hughenden Avenue...

  • Page 26: Water Connections

    Installation Water connections 3.9.1 Hydrojet system Fig. 6a Hydrojet System The heater is fitted with the Hydrojet Total Performance System incorporated in the cold inlet dip tube. The tube is designed to increase turbulence and reduce sediment build up, reduce thermal stacking and increase delivery.

  • Page 27: Vented Systems, Standard Range

    Installation 3.9.2 Vented systems, Standard Range Fig. 7 T&P Valve tapping The water heater must be supplied from a cold water feed Cold water inlet Hot water outlet cistern and the hot water supply pipe must be fitted with an open vent pipe in accordance with BS 5546 and BS 6644.

  • Page 28: Correx Powered Anodes

    Installation 3.9.3 Correx powered anodes Fitting and Operation Instructions Please note that the new HIflo Auto ignition range has Correx anodes fitted as standard. THE INTRODUCTION OF THIS KIT HAS THREE MAIN ADVANTAGES TO BE CONSIDERED a) LOW MAINTENANCE COSTS (Correx is non sacrificial, therefore no anode maintenance is needed).

  • Page 29: Test The Installation

    Unvented systems, standard range Unvented Systems should be fitted by an Approved Installer When used in an unvented system, the Andrews Water Heater will supply hot water at a pressure of 3.5bar provided that this pressure is available at the mains feed. During conditions of no- flow, system pressure may rise to a maximum of 6bar whilst the burner is operating.
  • Page 30 Installation The pipework fitted to the tundish outlet should be at least Fig. 11 28mm diameter and should be terminated at a suitable drain Terminal (see Building Regulations Approved Document G3). All fittings and materials must be suitable for use with drinking See table (page 9) water and listed in the current Water Research Centre Roof...

  • Page 31: Vented Systems, Hiflo Range

    Installation 3.9.7 Vented systems, HIflo Range The water heater must be fed from a cold water feed cistern or static water tank. Note A safety valve must be fitted as specified in BS 6644 Clause 9. The safety valve must be fitted either directly to an upper tank tapping or not further than 1 metre along the outlet flow pipe of size not less than the safety valve.
  • Page 32 Installation After Installation of the water system, open the main water supply valve, flush the system and fill the heater. Open the hot taps to allow air to escape from the system. When the system is free of air, close the taps and check for leaks at the gas control thermostats, drain cock and pipe connections on the heater.
  • Page 33 Installation Fig. 15 1.0m Roof Cold water feed Overflow Cold water inlet Hot water service pipe Drain & secondary Drain & secondary Common return tapping return tapping return Fig. 16 1.0m Roof Open vent Overflow water Cold water service feed pipe Cold water inlet...

  • Page 34: Unvented Systems, Hiflo Range

    Unvented systems, HIflo range Fig. 17 Unvented Systems should be fitted by an Approved Installer OPTIONAL PARTS When used in an unvented system, the Andrews Water Heater C4 temperature/ will supply hot water at a pressure of 3.5bar provided that this pressure relief pressure is available at the mains feed.
  • Page 35 Installation Fig. 19 1.0m Roof Hot water Cold service water pipe take off To drain Common return Cold water inlet Fig. 20 1.0m Roof Hot water Cold service water take off pipe To drain Cold water inlet Common return Issue 2 14/07/16...

  • Page 36: Commissioning

    Commissioning Commissioning Standard range permanent pilot models 4.1.1 Lighting the burner Fig. 21 Caution Do not operate the water heater until the storage vessel is completely filled with water, with water running from all hot taps. Open the main gas supply cock after all connections to the gas control are completed and test all connections, using proprietary leak detection fluid.

  • Page 37: Checking Main Burner Pressure

    Commissioning 4.1.3 Checking main burner pressure 1. Turn burner OFF as above. Fig. 22 2. Remove brass cap from pressure adjustment port. 3. Release bleed screw A one turn and connect pressure gauge tube. 4. Light burner according to the preceding instructions. 5.

  • Page 38: Shutting Off The Burner

    Commissioning 4.2.2 Shutting off the burner For long periods only, (7 days or more) turn control knob to PILOT, partially depress knob, then turn clockwise to OFF. Turn Fig. 24 off gas service cock. For shorter periods leave heater under thermostat control.

  • Page 39: Standard Range Auto Ignition Models

    Commissioning Standard Range Auto ignition models 4.3.1 Lighting the burner 1. Ensure gas supply is on. Fig. 26 2. Set thermostat control knob to the required water temperature. (See below). Thermostat control On/off switch 3. Ensure time switch if fitted is in the ON position. knob 4.

  • Page 40: Hiflo Range Auto Ignition Models

    Commissioning HIflo Range Auto ignition models 4.4.1 Lighting the burner 1. Ensure gas supply is ON. Fig. 28 2. Turn gas control knob to ON position. 3. Using control thermostat, select required water temperature. 4. Move electrical ON/OFF switch to ON. After a delay of about 10 seconds, the burner will light.

  • Page 41: Instructing The User

    Introduction Instructing the user 4.5.1 All Standard and HIflo models When satisfactory commissioning and testing has been achieved, hand this manual to the User or Purchaser and explain the method of economic and efficient operation. Explain that: 1. Other than for long shutdown periods, the heater must be left operating normally.

  • Page 42: Users Safety Guide

    Commissioning Users safety guide Note For your safety read before lighting the appliance Warning 1. Always follow manufacturers instructions when lighting the appliance. Failure to do so may result in damage to property, personal injury or loss of life. 2. Before lighting check all round the appliance area for gas.

  • Page 43: Operation

    Operation Operation Standard Range When properly installed and adjusted, the heater will require minimal attention. Should it become necessary to completely drain the heater, close the cold water inlet valve and open a hot water tap to allow air to enter the system. Fit a suitable hose to the drain cock and open.

  • Page 44: Hiflo And Standard Range Auto Ignition

    Operation HIflo and Standard Range Auto ignition 5.3.1 Auto ignition units, operating sequence. Hi- Flo and standard range 1. When the control thermostat senses too-cool water, a signal is sent to the control sequence unit. 2. The flue damper unit is de-energised and thus allowed to open.

  • Page 45: Servicing

    Servicing Servicing Introduction 6.1.1 Servicing must be carried out by a qualified person. Whilst giving these instructions for the care of the Heater, it is recommended that checks are carried out by the installer or local gas authority, at least annually. Ensure good ventilation by keeping the heater free of extraneous materials and clear of dust and lint.

  • Page 46: Burner Assembly Hiflo Range

    Servicing 5. Remove two screws securing main burner supply tube to bottom of burner to gain access to main jet. Remove main jet and clean with acetone. Blow through main burner with compressed air. CLEAN ORIFICES WITH WOOD SPLINTER. DO NOT USE SHARP METALLIC OBJECTS.

  • Page 47: Gas Control Valve Standard Range

    Servicing 7. Remove the burner and pilot injectors and clean with acetone. CLEAN ORIFICES WITH 8. Re-assemble in reverse order but note: i) The flueways and combustion chamber must be cleaned first. ii) Use an approved jointing compound when re-fitting burner injectors.

  • Page 48: Fuel Ways Standard Range

    Servicing Fuel ways standard range Note The flue ways should be checked and cleaned annually. 1. Remove burner as described in Burner Assembly, Standard Range. 2. Remove split flue clip from flue and lift off draught diverter. 3. Inspect and clean secondary flue installation as necessary. 4.

  • Page 49: Cleaning The Storage Vessel All Models

    Servicing Cleaning the storage vessel all models Note The storage vessel should be checked and cleaned annually. Scale formation in the base of the vessel may occur, particularly in hard water areas and is normally associated with high usage and high water temperatures. It is characterised by a rumbling noise when the main burner is lit.

  • Page 50: Magnesium Anode(S) All Models

    Servicing 6.10 Magnesium anode(s) all models Magnesium sacrificial anode(s) is (are) fitted to the top of the storage vessel. The anode(s) will prevent corrosion of the storage vessel. Anode condition should be checked annually and replaced if excessive wear is present. We recommend that the anode(s) are replaced annually.

  • Page 51: Replacing Components, Hiflo Range

    Replacing Components, HIflo Range Replacing components, HIflo Range Gas control valve Note Models 62/341, L62/309, 54/418, 54/440 and L54/399 are fitted with an anchor bracket between the burner manifold and the heater body. Remove two screws to release the anchor bracket. 1.

  • Page 52: Thermopile/ Pilot, Burner/ Pilot Restrictor

    Replacing Components, HIflo Range Thermopile / pilot, burner / pilot restrictor 1. Disconnect thermopile and pilot supply pipe from gas control valve. 2. Remove two screws and withdraw burner assembly. 3. Remove two screws and withdraw pilot assembly. 4. Unscrew gland nut securing thermopile to it's bracket and withdraw.

  • Page 53: Burner

    Replacing Components, HIflo Range Burner Note Models 62/341, L62/309, 54/418, 54/440 and L54/399 are fitted with an anchor bracket between the burner manifold and the heater body. Remove two screws to release the anchor bracket. 1. Turn off the gas control and the service cock. Disconnect union joint on service cock.

  • Page 54: Fault Finding

    Fault Finding Fault finding Permanent pilot models Standard and HIflo Ranges Fault Action WATER DOES (a) Check gas service cock is open. NOT GET HOT (b) Check water valves are open. (c) Check pilot is alight. (d) Check thermostat setting. reset to higher temperature. (e) Check gas pressures at burner and at gas inlet to appliance.

  • Page 55: All Models

    Fault Finding All models Fault Action HEATER SOOTING, (a) Check gas burner pressure and injector size. If possible, check heat input with meter and watch. YELLOW FLAME (b) Clean burners and injectors. (POOR COMBUSTION) (c) Flue obstruction. Clean flue ways. (d) Check flue design and termination position.

  • Page 56: Auto Ignition Units Hiflo Models

    Fault Finding Auto ignition units HIflo models Fault Action CONTINUOUS (a) Check gas service cock is open. IGNITION NO (b) Check gas control knob is ON. PILOT FLAME (c) Check ECO for failure. PILOT LIGHTS BUT (a) Main gas valve not energised, opal light is on. Check for loose contacts. MAIN BURNER (b) Check for 24V AC at intermittent pilot ignition control terminal No.

  • Page 57: Lpg Permanent Pilot Models - Lpg Hiflo Ranges

    Fault Finding LPG permanent pilot models - LPG HIflo ranges Fault Action Loud whistling noise Check burner primary air shutter settings are correct to dimensions given below. If not reset to dimensions given below. If the whistling persists continue to reduce the settings until the whistling stops. Heater Model Air shutter dimension A in mm L32/143...

  • Page 58: Parts List And Illustrations

    Parts List and Illustrations Parts list and illustrations Standard Range models 24/29, 32/40, 40/61, 63/62 (Natural Gas) Fig. 30 Standard Range model 84/87 (Natural Gas) Fig. 31 Issue 2 14/07/16...

  • Page 59: Standard Range Models Parts List (Natural Gas)

    Parts List and Illustrations Standard Range models parts list (Natural Gas) Model 24/39 32/40 40/61 63/62 84/87 Ref. Part Numbers Description C654 C654 C654 C657 C657 Adaptor Ring C653 C653 C655 C656 C658 Draught Diverter C285 C285 C285 C285 C690...

  • Page 60: Standard Range Lpg Models L24/31, L32/35, L40/36, L63/71

    Parts List and Illustrations Standard Range LPG models L24/31, L32/35, L40/36, L63/71 Fig. 31 Standard Range LPG model L84/74 Fig. 31 Issue 2 14/07/16...

  • Page 61: Standard Range Models Parts List (Lpg)

    Parts List and Illustrations Standard Range models parts list (LPG) Part Description L24/31 L32/35 L40/36 L63/71 L84/74 Number C654 Adaptor Ring • • • C657 Adaptor Ring • • C653 Draught Diverter • • C655 Draught Diverter • C656 Draught Diverter •...
  • Page 62 Parts List and Illustrations Part Description L24/31 L32/35 L40/36 L63/71 L84/74 Number C114 Pilot Knob • • • • • C316 Pilot Injector N11 • • • • • C412 Pilot Burner Complete • • • • • C464 Top Cover Outer Jacket •...

  • Page 63: Hiflo Models 32/143 (Natural Gas)

    Parts List and Illustrations HIflo model 32/143 (Natural Gas) Fig. 32 HIflo models 65/173 and 81/264 (Natural Gas) Fig. 33 Issue 2 14/07/16...

  • Page 64: Hiflo Models Parts List (Natural Gas)

    Socket Coupler 3/4” E021 C475 C476 Data Badge C533 C536 C540 Flue Baffle C235 C235 C235 Andrews Label C479 C479 Hot Outlet Connection, 1 1/2” BSP E056 E055 Hydrojet Cold Inlet Connection (top) 1 1/2” BSP C486 C486 C486 Top Cover C488...

  • Page 65: Hiflo Models 62/341 And 54/418/440 (Natural Gas)

    Parts List and Illustrations 9.10 HIflo models 62/341 and 54/418/440 (Natural Gas) Fig. 34 Issue 2 14/07/16...

  • Page 66: Hiflo Models Parts List (Natural Gas)

    Drain Cock, BS 2879, 3/4” C103 C103 Socket Coupler 3/4” C474 C473/C492 Data Badge C543 Flue Baffle C543 Flue Baffle C235 C235 Andrews Label C487 C554 Top Cover C488 C488 Insulation Pad C490 E392 Flue Box Top Cover C694 C694 Cleanout Pad Seal...

  • Page 67: Hiflo Lpg Model L32/143

    Parts List and Illustrations 9.12 HIflo LPG model L32/143 Fig. 31 9.13 HIflo LPG models L65/169, L81/251 Fig. 31 Issue 2 14/07/16...

  • Page 68: Hiflo P.p Water Heater Parts List (Lpg)

    Data Badge • C533 Flue Baffle • C536 Flue Baffle • C540 Flue Baffle • C235 Andrews Label • • • C479 Hot Outlet Connection 1 1/2” BSP • • E056 Hydroject Cold Inlet Connection • E055 Hydroject Cold Inlet Connection •...

  • Page 69: Hiflo Lpg Models L62/309, L54/399

    Parts List and Illustrations 9.15 HIflo LPG models L62/309, L54/399 Fig. 31 Issue 2 14/07/16...

  • Page 70: Hiflo P.p Water Heater Parts List (Lpg)

    • C496 Data Badge • C497 Data Badge • C543 Flue Baffle • C540 Flue Baffle • C235 Andrews Label • • C487 Top Cover • C554 Top Cover • C488 Insulation Pad • • C490 Flue Box Top Cover •...

  • Page 71: Unvented Systems Kit - Standard Range

    Parts List and Illustrations 9.17 Unvented systems kit - Standard Range Fig. 35 9.18 Unvented systems kit - HIflo range Fig. 36 Issue 2 14/07/16...

  • Page 72: Unvented Systems Kit - Standard Range Parts List

    Parts List and Illustrations 9.19 Unvented systems kit - Standard Range parts list Ref. Part No. Description B171 Unvented Systems Kit Complete C780 Pressure Reducing Valve / Strainer C781 Check Valve / Expansion Valve C782 Expansion Vessel E462 Temperature / Pressure Relief Valve C783 Tundish C772...

  • Page 73: Volt Auto System Kit B217

    Parts List and Illustrations 9.21 24 Volt auto system kit B217 Fig. 37 9.22 24 Volt auto system kit B258 Fig. 38 Issue 2 14/07/16...

  • Page 74: Volt Auto System Kit Standard Range Parts List

    Part No. Description B258 240 Volt Auto System Kit E839 Pilot Assembly C521 On / Off Switch C531 Label - Andrews C644 Label - Warning C989 Label - On / Off Label - Wiring Z090 Gas Control Valve E669 Control Circuit Board...

  • Page 75: Appendix

    Appendix 10 Appendix 10.1 HIflo auto ignition “G” series addendum 10.1.1 Features of Honeywell integrated controls system • Attractive digital water heater display on control panel for setting and displaying the temperature setpoint. Pressing temperature up and down buttons changes the temperature setpoint.

  • Page 76: Sequence Of Operations

    Appendix 10.3 Sequence of operations 1. Thermostat calls for heat. Fig. 39 The control board sends 24 volts from damper terminal #2 on the control plug to the flue damper. CONNECTION DIAGRAM 2. Flue damper begins to rotate open. Once the flue damper is UPPER LOWER SENSOR...

  • Page 77: Troubleshooting

    Appendix 10.4 Troubleshooting Caution Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals Water Heater Fault: Water heater does not operate Check main power supply to water heater - fuse, circuit Display Error Code: Water heater display does not operate - breaker, plug receptacle, line blank display cord or wiring to water heater.
  • Page 78 Appendix Caution Use Caution Not to Damage Connectors when making Voltage Measurements or Jumping Terminals From previous page Error code #55 on display. Does water heater begin to Does damper blade move to Remove damper from heater operate? the full open position? and jump black &...

  • Page 79: Using Control Display For Servicing The Water Heater

    Appendix 10.4.1 Using control display for servicing the water heater ACCESSING SERVICE MODE ON THE WATER HEATER DISPLAY (FOR SERVICE PERSONNEL ONLY) The display has a “service mode” for changing the maximum setpoint and accessing information in aiding servicing of the water heater.

  • Page 80: Service Mode

    Appendix 10.4.2 Service mode Error code Fig. 43 shown in water The following is the sequence of modes available in heater display “Service Mode” by pressing the “Select” button: Error Code Number (Display/Reset). This is only shown if there is an operating error in the “User Mode”. Max setpoint value in Fig.
  • Page 81 Appendix Fig. 47 2c. Water Temperature - Lower Sensor (Displays if there are two sensors) Fig. 48 3. Flame Current of Pilot Flame Sensor (Displays only in the Heating Cycle) Fig. 49 4. Setpoint (Display/Change) Fig. 50 5. °F/°C (Display/Change) Issue 2 14/07/16...
  • Page 82 Appendix Fig. 51 6. Differential (Display only - shows the differential of the thermostat) Fig. 52 7. Software Version (Display only) Fig. 53 8. Error Code History (Displays if there are present error codes or up to 10 previous error codes). Water Heater Display will show a “--“...

  • Page 83: To Change The Maximum Setpoint Limit (Max Setpoint) For The Temperature Setpoint

    Appendix 10.4.3 To change the maximum setpoint limit (max setpoint) for the temperature setpoint: Fig. 54 Step 1: In service mode press the “Select” button until “Max Setpoint” is displayed. Fig. 55 “Max setpoint” flashes Step 2: Press “Set” button to enter setting mode. “Max Setpoint”...

  • Page 84: Display Of Water Temperature

    Appendix Fig. 58 Step 5: 30 Seconds after the last button press, the Water Heater Display will go back to “User Mode”. It will read “Max Setpoint” without showing a temperature value if the temperature setpoint is at the maximum setting.

  • Page 85: To Display Flame Sense Current Of The Pilot Flame Sensor

    Appendix 10.4.5 To display flame sense current of the pilot Fig. 62 flame sensor The pilot flame sense current is available only when the burners are in operation. Step 1: Make sure the status displays “Heating” or draw enough hot water to start the burners. Step 2: Enter the “Service Mode”...

  • Page 86: To Display And Change Temperature Format (°F/°C)

    Appendix Fig. 66 “Setpoint” flashes Step 4: To lower the temperature setpoint, press the “Temperature Down” button until the desired temperature is shown on the water heater display. Fig. 67 “Setpoint” stops flashing Step 5: When the desired setpoint is reached on the water heater display, press the “Set”...
  • Page 87 Appendix Fig. 70 Changes to “°C” “F/°C” flashes Step 3a: Press “Temperature Up” button to change temperature format to °C Fig. 71 Changes to “°F” “F/°C” flashes Step 3b: Press “Temperature Down” button to change temperature format to °F Fig. 72 “F/°C”...

  • Page 88: Error Codes And Error History Display

    Appendix 10.4.8 Error codes and error history display Fig. 74 If there is an operating problem with the water heater, an error Example of Error Code in the Display code number will appear on the water heater display with “Service Needed” to the right of the “Status” indicator. The error code label is located under the water heater display.
  • Page 89 Appendix Fig. 78 Error code index Step 4: Press the “Temperature Down” button to change to the previous code index, code #9. Fig. 79 Stored error code for code index #9 Step 5: Press the “Select” button for code index #9 to view if there are any code numbers.

  • Page 90: Error Code Definitions

    Appendix 10.4.11 Error code definitions If the water heater has an operating problem, there will be a number in the water heater display with “Service Needed” shown below the error code number. Note the error code and the definition in the chart below. This label appears on the control box under the water heater display.

  • Page 91: Resetting Lockout Conditions

    Appendix 10.4.12 Resetting lockout conditions Warning Fig. 81 Fig. 81 The following procedure is for service and installation personnel only. Resetting lockout conditions without Error code shown in correcting the malfunction can result in a hazardous water condition. heater display If an error code is displayed (except for #4, low flame sense current), the water heater will be in a “lockout condition”...

  • Page 92: Service Procedure

    Appendix 10.5 Service procedure D24-I 10.5.1 Thermostat circuit testing Condition: Water Heater Not Operating Display shows error code Danger “31” (Upper Sensor Readings Faulty) 120 volt exposure. To avoid personal injury, use caution or error code “32” (Lower Sensor while performing this procedure. Readings Faulty) Caution Unplug or disconnect electrical power to...
  • Page 93 Appendix Warning Do not operate water heater without verifying that the overheating condition has been corrected. From previous page Condition: Water Heater Not Operating Display shows error code “65” High Water Temperature (over 93°C) Continued Once cause of overheating condition has been diagnosed and corrected, the control may be reset •...

  • Page 94: Sensor Resistance Testing

    Appendix 10.5.2 Sensor resistance testing Fig. 85 Upper Sensor Upper thermistor location (applicable models) 1. Determine resistance value of upper sensor. Test across grey wires. 2. Draw quart of water off T&P valve. Using a thermometer, determine water temperature. 3. Use table below to verify correct resistance per water Lower thermistor temperature measured.

  • Page 95: Service Procedure D24

    Appendix 10.6 Service procedure D24-II 10.6.1 Pilot operation testing Danger 120 volt exposure. To avoid personal injury, use caution while performing this procedure. Caution Be Careful When Making Voltage Measurements or Condition: Jumping Terminals Not to Damage or Deform Connectors Pilot will not light or stay lit, Error or Connector Pins.

  • Page 96: Pilot Inspection

    Appendix 10.6.2 Pilot inspection Condition: Error code 57: Flame Rod Shorted to Ground Disconnect power. Shut off gas Check to see if pilot shield is supply to water heater. Slide out touching pilot flame sensor or Check pilot flame sense wire for burner assembly (see section on flame sensor touching pilot hood.

  • Page 97: Pilot Operation Testing

    Appendix 10.6.3 Pilot operation testing Danger 120 volt exposure. To avoid personal injury, use caution Condition: while performing this procedure. Pilot lights, no or low flame signal. Control Display shows “4” or “62” Caution for Error Codes (Service Needed). Be Careful When Making Voltage Measurements or Control continues to spark until Jumping Terminals Not to Damage or Deform Connectors system “Lock Out”.

  • Page 98: Service Procedure D24

    Appendix 10.7 Service procedure D24-III 10.7.1 Main burner operation testing Danger 120 volt exposure. To avoid personal injury, use caution while performing this procedure. Caution Be Careful When Making Voltage Measurements or Jumping Terminals Not to Damage or Deform Connectors or Connector Pins.

  • Page 99: Checking Manifold Pressure

    Appendix 10.7.2 Checking manifold pressure Condition: Danger Main burner short cycles. Control 120 volt exposure. To avoid personal injury, use caution Display may show error code “63, while performing this procedure. 57, or 4” and be in “Soft Lockout” state. Caution Be Careful When Making Voltage Measurements or Check gas inlet pressure to the...

  • Page 100: Service Procedure D24

    Appendix 10.8 Service procedure D24-IV 10.8.1 Main burner & pilot removal and inspection Warning Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Main burner removal Step 1. Disconnect (un-plug) water heater from electrical supply.

  • Page 101: Control Board Replacement

    Appendix Pilot burner removal Step 1. With burner rack removed from heater, disconnect pilot tube connection from gas valve Step 2. Remove the two pilot burner mounting screws securing the pilot and pilot shield in place. Step 3. Remove pilot shield and pilot from burner rack. Step 4.

  • Page 102: Service Procedure

    Appendix 10.9 Service procedure D24-V 10.9.1 Flue baffle removal and inspection Warning Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 1. Disconnect (unplug) water heater from electrical supply.

  • Page 103: Service Procedure D24

    Appendix 10.10 Service procedure D24-VI 10.10.1 Anode removal and inspection Warning Heater components may be HOT when performing the following steps in this procedure. Take necessary precaution to prevent personal injury. Step 1. Disconnect (unplug) water heater from electrical supply. Step 2.
  • Page 104 Appendix Step 13. Upon completion of inspection or subsequent replacement, reinstall anode rods into water heater. Step 14. Check for leaks. Step 15. Reinstall collector cover & insulation over collector cover. Step 16. Reinstall jacket head, flue damper and draft diverter. Reconnect venting.

  • Page 105: General Assembly

    Appendix 10.11 General assembly Parts table - page 98 Fig. 89 Powered anodes are located in front for models 65/173 auto GB and 81/264 auto GB. All other models use rear location. Issue 2 14/07/16...

  • Page 106: Burner Assembly

    Appendix 10.12 Burner assembly Parts table - page 99 Fig. 90 Issue 2 14/07/16...

  • Page 107: Control Box Assembly

    Appendix 10.13 Control box assembly Parts table - page 100 Fig. 91 Issue 2 14/07/16...

  • Page 108: General Assembly Parts List

    Appendix 10.14 General assembly parts list: ref fig 89 - page 95 Item Part Number Description 32/143 54/440 62/341 65/173 81/264 Number New Auto New Auto New Auto New Auto New Auto Z157 Draft Diverter c/w Leg • Z158 Draft Diverter c/w Leg •...

  • Page 109: Burner Assembly Parts List

    Appendix 10.15 Burner assembly parts list: ref fig 90 - page 96 Item Part Number Description 32/143 54/440 62/341 65/173 81/264 Number Auto New Auto New Auto New Auto New Auto Z203 Burner Rack • • • Z204 Burner Rack •...

  • Page 110: Control Box Assembly Parts List

    Appendix 10.16 Control box assembly parts list: ref fig 91 - page 97 Item Part Number Description 32/143 54/440 62/341 65/173 81/264 Number Auto New Auto New Auto New Auto New Auto Z248 Gas Control Valve Harness • • • •...

  • Page 111: Dismantling, Disposal And Recycling

    Appendix 10.17 Dismantling, disposal and recycling Warning Only qualified competent persons should remove and dismantle the appliance. Before removing and dismantling please ensure you safely remove the power supply and isolated the appliance from the water and gas connections. Dispose of the appliance correctly according to the laws and regulations in force.
  • Page 112 Issue 2 14/07/16...
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  • Page 114 Issue 2 14/07/16...
  • Page 115 © Copyright All technical and technological information contained in these technical instructions, as well as any drawings and technical descriptions supplied, remain our property and shall not be multiplied without our prior consent in writing. Subject to alterations.
  • Page 116 0345 070 1055 Technical Technical 0345 070 1057 0345 070 1057 0345 070 1057 ICOM ICOM Website ebsite Energy Association Energy Association andrewswaterheaters.co.uk andrewswaterheaters.co.uk Twitter witter @AndrewsWH @AndrewsWH Andrews. Built to perform. Andrews. Built to pe Andrews. Built to pe form.

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