andrews COMBIflo 100/300 Installation, Operation And Maintenance Manual
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andrews COMBIflo 100/300 Installation, Operation And Maintenance Manual

Indirect high effi ciency boiler & stainless steel storage water heater
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INSTALLATION OPERATION AND MAINTENANCE MANUAL
COMBIfl o
Indirect High Effi ciency Boiler & Stainless Steel Storage Water Heater
100/300, 150/300
M7889

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Summary of Contents for andrews COMBIflo 100/300

  • Page 1 INSTALLATION OPERATION AND MAINTENANCE MANUAL COMBIfl o Indirect High Effi ciency Boiler & Stainless Steel Storage Water Heater 100/300, 150/300 M7889...
  • Page 2 Technical Parameters COMBIflo COMBIflo Model 100/300 150/300 Space heating parameters Condensing boiler Low-temperature boiler(1) B1 boiler Cogeneration space heater Combination boiler Rate heat output rated Useful heat output at rated heat output and high 91.5 136.8 temperature regime(2) Useful heat output at 30% of rated heat output and low 29.9 43.9 temperature regime(1)

  • Page 3: Table Of Contents

    Final checks and user handover ..........Fault fi nding ................Maintenance Routine Inspection intervals & requirements ....... Removing and changing components ........Component parts list ..............Component illustrations .............. Recommended spares requirements ......... Fault code table ................ANDREWS COMBIfl o...

  • Page 4: Description Of Appliance

    1.1 DESCRIPTION OF APPLIANCE This Andrews COMBIfl o is a gas fi red, low No×, multi- heat engine cascading boiler system, with an integrated 5” Low Loss Header for the supply of a low temperature hot water space heating system. The COMBIfl...

  • Page 5: Symbols Used In This Guide

    Indicates serious danger from electricity to personal safety and life CAUTION! Indicates a potentially dangerous situation for the boiler and the environment INFORMATION Suggestions to assist the user in implementing instructions in this guide ADDITIONAL READING Reference to additional information in other documents ANDREWS COMBIfl o...

  • Page 6: Safety

    This heater is designed to be used in a domestic hot water supply and storage system. Any other use of this heater will be considered improper. Andrews Water Heat- ers declines any responsibility for any damage or injuries caused by an improper use. In order to use the heater according to its designed scope, it is essential to carefully follow the instructions given in this guide.

  • Page 7: Regulations And Standards

    IGE/UP/16 - Design for Natural Gas installations on industrial and commercial premises with respect to hazardous area classifi cation and preparation of risk assessments CAUTION These manufacturer’s notes must not be taken in any way as over-riding statutory obligations. ANDREWS COMBIfl o...

  • Page 8: Ukca & Ce Marking

    - Low Voltage (LVD) Directive 2014/35/EU - Boiler Effi ciency (BED) Directive 92/42/EEC This manual is an integral and indispensable part of the appliance and it is suggested that this manual is kept in a safe place for future reference. ANDREWS COMBIfl o...

  • Page 9: Technical Data

    3.0 TECHNICAL DATA 3.1 GENERAL DIMENSIONS & CONNECTIONS ANDREWS COMBIfl o...

  • Page 10: Performance Data

    2 1/4” 2 1/4” Tank drain WEIGHTS & CLEARANCES Weight empty (full) 290 (608) 320 (641) Service clearance - rear Service clearance - right (with immersion) 300 (600) 300 (600) Service clearance - top Service clearance - left ANDREWS COMBIfl o...

  • Page 11: System Schematic

    3.3 SYSTEM SCHEMATIC ANDREWS COMBIfl o...

  • Page 12: Application Examples

    3.4 APPLICATION EXAMPLES Single Heating Circuit (Simple) ANDREWS COMBIfl o...
  • Page 13 Single Heating Circuit + Immersion + DHW Circulation pump ANDREWS COMBIfl o...
  • Page 14 Mixer Heating Circuit 1 with Room Control + Heating Circuit 2 + Heating Circuit 3 (Weather Compensation) ANDREWS COMBIfl o...
  • Page 15 Mixer Heating Circuit 1 + Mixer Heating Circuit 2 + Mixer Heating Circuit 3 (Room + Weather Compensation) ANDREWS COMBIfl o...
  • Page 16 Heating Circuit - External 0-10V control ANDREWS COMBIfl o...
  • Page 17 BMS & INTERNET CONNECTIONS ANDREWS COMBIfl o...

  • Page 18: Wiring Diagrams

    3.5 WIRING DIAGRAMS PCB 1 ANDREWS COMBIfl o...
  • Page 19 PCB 2 & 3 ANDREWS COMBIfl o...

  • Page 20: Sensor Values

    Resistance (Ohms) (Ohms) 7578 1690 5861 1621 4574 1555 3600 1492 3435 1433 3279 1375 3131 1320 2990 1268 2857 1218 2730 1170 2610 1125 2496 1081 2387 1040 2284 1000 2186 2093 2004 1920 1840 1763 ANDREWS COMBIfl o...

  • Page 21: Installation

    SPLIT UNIT WEIGHT & DIMENSIONS LH HEATER SECTION RH TANK SECTION 100 Weight = 175 kg 150 Weight = 205 kg 100 Weight = 85 kg 150 Weight = 85 kg 1090mm(L) x 655mm(W) x 1950mm(H) 600mm(L) x 600mm(W) x 1950mm(H) ANDREWS COMBIfl o...

  • Page 22: Locating The Appliance

    2. Drill marked position on fl oor to allow installers preferred method of fi xing. 3. Refi t plate and fasten through using preferred fi xing method. 4. Repeat method for the other three corner fi xing points. Slide plate onto corner support ANDREWS COMBIfl o...

  • Page 23: New & Existing Heating Systems

    This will result in Chlo- ride concentration and premature boiler failure if left untreated. If Chloride concentration levels have exceeded 200mg/l, the system should be fl ushed clean and refi lled with low Chloride water and appropriate system treatments. ANDREWS COMBIfl o...

  • Page 24: Water Connections

    Water treatment is usually recom- base exchange water mended when the hardness levels measures greater than 150 ppm. For this reason, treatment is strongly recommended in hard water areas. ANDREWS COMBIfl o...

  • Page 25: Open Vent Design

    The distance from the normal water level to the top of the cistern should comply with that specifi ed by the Water Authorities. 4.6.1 DE-STRATIFICATION PUMP By virtue of its design, an internal DHW tank de-stratifi cation pump is not required. ANDREWS COMBIfl o...

  • Page 26: Unvented Design

    Part G of Schedule 1 of the Building Regulations. Water Temperature & Pressure Relief Valve Expansion Vessel Wall Bracket Assembly Cold Water Inlet of Water Hose Assembly Check Valve Pressure Reducing Expansion Valve Valve/Strainer Tundish Cold Water Feed Balanced Cold Water Take-off (if required) ANDREWS COMBIfl o...

  • Page 27: Secondary Return Design (Dhw Circulation Pump)

    It is important that the condensate fl ow must be maintained, even in freezing conditions. In the event that the condensate becomes blocked, the appliance will shutdown completely, and will not operate again until the fl ow has been restored. ANDREWS COMBIfl o...

  • Page 28: Immersion Heater

    Once heater is fi rmly screwed into boss, fi ll the tank with water and check for leaks at maximum operational pressure. Install electrical supply to immersion heater according to the manufacturers instructions, ensuring that the heater is wired with heat resisting or mineral insulated cables complying with BS6207. ANDREWS COMBIfl o...

  • Page 29: Mixing Valve And Actuator Control

    QX22 (Y2) to close the valve until the temperature fall was detected by sensor B1. Precise temperature control is maintained by alternating 230V via QX21 & QX22 until the desired temperature is maintained, at which point no voltage maintains the valve position. ANDREWS COMBIfl o...

  • Page 30: Flue Systems And Ventilation

    CAUTION The installer is responsible for ensuring that the right type of fl ue system is used and that the diameter and length are correct. Only the accessories supplied by Andrews will ensure that the correct system components are used.
  • Page 31 If the air change rate is less than 0.5 changes per hour the following minimum free vent area will be as follows:- Model Position of vent <50% Summer use >50% and <75 Summer usage >75% summer usage COMBifl o 100 High & low level 188cm 282cm 375cm COMBIfl o 150 High & low level 280cm 420cm 560cm ANDREWS COMBIfl o...

  • Page 32: Flue Terminal Positions

    Above a pitched roof From a roof structure 2,500 2,500 2,500 2,500 Above a fl at roof From any other roof fl ue terminal 1,730 2,170 1,110 +Not Recommended - Risk assessment required ++ Plume management recommended ANDREWS COMBIfl o...

  • Page 33: Maximum Fl Ue Lengths

    When the combustion fl ue system required is longer than 5m, it is recommended that a separate system to capture excess condensation formed inside the fl ue is fi tted. ANDREWS COMBIfl o...

  • Page 34: Gas Connections

    Check for gas tightness (BS. 6891) in pipework to the appliance by connecting a manometer to the inlet pres- sure tapping point.(See Fig. 4.1) Gas and combustion soundness within the appliance should be checked using sense of smell and leak detection fl uid. Ensure gas tightness before moving onto commissioning. ANDREWS COMBIfl o...

  • Page 35: Electrical Connections

    Burner On - When any of the appliances heat engines are in operation, an internal relay will activate and close the circuit to indicate that at least one heat engine is in operation. ANDREWS COMBIfl o...

  • Page 36: Agu2.5 Expansion Modules

    5. Solar DHW Q5 (pump) B6 (Collector B31 (DHW sensor) tank sensor) 6. Primary controller Y19 (open Y20 (close Q14 (pump) B15 (fl ow sen- mixer valve) mixer valve) sor) * Can be freely confi gured ANDREWS COMBIfl o...
  • Page 37 The operation of the primary pump with each heating circuit and DHW will need to be determined by setting parameters 872, 1172, 1472 or 1880. * Please see separate ‘CONTROLS PROGRAMMING GUIDE’ guide supplied with heater for further details on how to confi gure these modes ANDREWS COMBIfl o...

  • Page 38: Web Server Ozw672

    • Function “Energy indicator” to monitor data points for energy-related limit values, or “Green limits” and send to 2 email recipients. • Periodically (daily, weekly or monthly) send system reports to a maximum of 4 e-mail recipients. ANDREWS COMBIfl o...
  • Page 39 4.18.1 CONNECTING WEB SERVER OZW672 TO THE APPLIANCE Paying careful consideration to the manufacturers instructions which accompany the OZW672, the following wiring op- tions are recommended: For commissioning and operation of the OZW672 please refer to the Siemens guide accompany- ing the device. ANDREWS COMBIfl o...

  • Page 40: Outside Sensor And Wired Room Units

    (about 1.5 metres above the fl oor) See illustration on the following page for guidance on sensor positioning ANDREWS COMBIfl o...
  • Page 41 Up to a maximum of three room units can be connected to the same set of QAA connections inside the COMBIfl o wiring centre. The base provides the power for QAA55. When the room units are removed from the base, power is cut off (i.e. the units are out of operation). ANDREWS COMBIfl o...
  • Page 42 - Operation changeover heating circuit. - Readjustment of comfort setpoint. - Changeover of operating level (occupancy button) A setpoint readjustment with the knob is adopted either by pressing the operating mode button or with- out any further confi rmation (time-out). ANDREWS COMBIfl o...
  • Page 43 AGU2.5), the setup of the manual thermostat, for the control of a heating zone is as follows: Line Display Notes 6046/6054/6062 Defi ne function input H2 Setup as “Room thermostat HC1, HC2 or HC3” 6047/6055/6063 Defi ne contact type H2 Normally open or normally closed ANDREWS COMBIfl o...

  • Page 44: Filling And Removal Of Air

    The heat engines and Low Loss Header (LLH) must be completely full of water and devoid of all trapped air. Failure to remove air from the heat exchangers can result in permanent damage and failure of the appliance. Fill / drain point Pressure relief valve ANDREWS COMBIfl o...
  • Page 45 CAUTION It is ESSENTIAL that all air is removed from the heater before proceeding with commissioning the heat engines , otherwise permanent damage may occur to the heat exchangers and this damage is not covered by warrantee. ANDREWS COMBIfl o...

  • Page 46: Commissioning Of Heat Engines

    As this appliance contains several heat engines, the manufacturer recommends that commissioning is carried out using Siemens OCI700 service tool or the Andrews commissioning tool, available directly from the manufacturer. If neither of these tools are available to the commissioning agent, then the following manual procedure can be used:- 5.2.2 HEAT ENGINE ONE (TOP MOST UNIT) COMMISSIONING...
  • Page 47 If you are experiencing CO readings that exceed 250ppm after 30 minutes of burner operation, please fi rst check that your gas analyser is functioning correctly and then contact Andrews Water Heaters on the customer support number given on the rear cover of this manual, for advice.
  • Page 48 If you are experiencing CO readings that exceed 250ppm after 30 minutes of burner operation, please fi rst check that your gas analyser is functioning correctly and then contact Andrews Water Heaters on the customer support number given on the rear cover of this manual, for advice.
  • Page 49 If you are experiencing CO readings that exceed 250ppm after 30 minutes of burner operation, please fi rst check that your gas analyser is functioning correctly and then contact Andrews Water Heaters on the customer support number given on the rear cover of this manual, for advice.

  • Page 50: Conversion To Lpg

    10. Allow one minute between adjustments, and do not move the adjuster more than 1/8 turn at any one time. 11. Replace the cover over the throttle screw, when adjustment is complete. 12. Affi x the new LPG serial number data label supplied with the heater over the top of the existing NG data plate. ANDREWS COMBIfl o...

  • Page 51: Frost Protection And Legionella

    30 seconds each. This will occur even if the appliance is in standby mode. This function is automatic and is designed to help prevent pumps from sticking if the appliance has not been in opera- tion for some time. ANDREWS COMBIfl o...

  • Page 52: Fault Finding

    5.6.2.1 FAULT DISPLAY EXAMPLES The display will show a if the appliance has recorded a fault. More information can be obtained by selecting the info pages menu . See example screen: Fault symbol Info pages ANDREWS COMBIfl o...

  • Page 53: Maintenance

    Gas valve connections Fan connectors Gas valve fl ange bolts Air snorkel Air control valve Gas valve vacuum tube Spark electrode Ionisation electrode Door nuts (x4) ANDREWS COMBIfl o...
  • Page 54 fi ve minutes before scrubbing with a nylon brush and fi nally rinsing away all deposits with clean water, until the condense pipe runs clear. • At the end of the cleaning process unscrew the condense trap bowl, clean out and refi t. • Assembly is the reverse. ANDREWS COMBIfl o...
  • Page 55 Disconnect any pipework connections to allow removal of the Tank Inspection Hatch at the top of the unit on RH side. Remove foam insulation to reveal Tank Inspection Hatch. Loosen nut on Tank Inspection Hatch to remove Hatch and inspect storage tank. ANDREWS COMBIfl o...

  • Page 56: Removing And Changing Components

    The LLH sensor is fi tted into the top of the LLH in the rear top left hand side of the appliance. • Undo the securing screw and withdraw sensor from pocket. • Unplug connector from loom. • Cut off securing tie and remove sensor. • Replacement is the reverse ANDREWS COMBIfl o...
  • Page 57 Unplug the cable from the rear of the GUI • Use a small fl at edged screwdriver release the GUI from its opening, by compressing the four plastic edge clips and gently pulling display out the front of the opening • Replacement is reverse ANDREWS COMBIfl o...
  • Page 58 • Carefully pull off the mains connections (pull back locking tab) and ignition cable from the spark genera- tor. • Release the screws holding the spark generator to the bracket (do not fully remove), and remove. • Replacement is the reverse. ANDREWS COMBIfl o...
  • Page 59 • Drain as much of the primary and secondary systems water as possible, to reduce water spillage. • Release all four heat exchanger connections and slide the heat exchanger toward the rear, and remove sideways • Replacement is the reverse. ANDREWS COMBIfl o...
  • Page 60 • Remove the vacuum air tube from the gas valve. • Using a pair of pliers, compress the Hose clip and pull hose off venturi. • Pull other end slowly off the air intake manifold. • Replacement is the reverse. ANDREWS COMBIfl o...
  • Page 61 • After fi ve minutes check the rate and combustion is correct to the table on page 8. Adjust using tle screw on the gas valve clockwise to decrease CO , anti-clockwise to increase CO if required. (see 5.2.1 for details) ANDREWS COMBIfl o...
  • Page 62 • Disconnect the gas valve from the venturi by removing the three securing screws Heat exchanger door screws • Remove the whole burner system using the four retaining nuts holding the heat exchanger door to the body. ANDREWS COMBIfl o...
  • Page 63 Isolator valve • Unscrew by hand the sensor • Replacement is the reverse NOTE: It is important not to over-tighten the water pressure sensor during fi tting. The maximum permissible tightening torque is 2Nm (approximate to hand tight). ANDREWS COMBIfl o...
  • Page 64 • Transfer the supply lead to the new pump. • When replacing the electrical connector, ensure the screw lines up with the receiver and then apply gentle pressure to the connector whilst tightening the screw. • Refi ll and check for leaks. ANDREWS COMBIfl o...
  • Page 65 • Undo the unions at the top and bottom of the pump body and remove pump (have a receptacle ready to catch any escaping water). • Replacement is the reverse. Fit the new pump seals suppied with the replacement pump. • Refi ll and check for leaks. ANDREWS COMBIfl o...

  • Page 66: Component Parts List

    5139795 DHW tank charging temperature sensor 5139797 Air pressure switch (condense line) 5142695 OC1345 communication device (c/w cable) 5139792 AVS74 Graphical User Interface 5142711 On / Off power switch 5142705 Reset switch 5142706 LMS Interface PCB 5142707 ANDREWS COMBIfl o...
  • Page 67 AGU2.5 clip-in extension 5139793 QAC34 Out-side sensor 5104726 LPG 5.2mm Orifi ce 7669653 Optional QAD36 Flow temperature sensor 5103867 Optional QAA55 Programmable room thermostat 5138511 Optional Commissioning controller 5141599 LPG Conversion kit 100/300 7669650 LPG Conversion kit 150/300 7669651 ANDREWS COMBIfl o...

  • Page 68: Component Illustrations

    6.4 COMPONENT ILLUSTRATIONS ANDREWS COMBIfl o...
  • Page 69 6.4 COMPONENT ILLUSTRATIONS (CONTINUED) ANDREWS COMBIfl o...
  • Page 70 6.4 COMPONENTS ILLUSTRATIONS (CONTINUED) ANDREWS COMBIfl o...

  • Page 71: Recommended Spares Requirements

    5139787 - Ionisation electrode c/w gasket and screws • 5139794 - Flow & return temperature sensors • 5139795 - Low loss header sensor • 5139777 - Combustion fan • 5139779 - Gas valve • 5142701 - Heat engine pump (Q1) ANDREWS COMBIfl o...

  • Page 72: Fault Code Table

    Maintenance message Item requiring attention but not preventing heater operation (e.g. 12 Month service due). Check details of message on the heater Front GUI screen. ANDREWS COMBIfl o...
  • Page 73 Check CO levels at min and max output. Safety time exceeded Ignition unsuccessful after 5 attempts within a 24 hour period. Check ignition and gas circuits for possible faults. ANDREWS COMBIfl o...
  • Page 74 Increase water pressure by adding water to system, as necessary Input BX, same sensors BX sensor duplicated - check parameters Input BX/extension module, BX extension module sensor duplicated - check parameters same sensors Extension module, same function Any Extension Modules duplicated - check parameters ANDREWS COMBIfl o...
  • Page 75 When the ing mode (No fault displayed) heater is operating via the volt free enable signal, it is not possible to operate the heater manually via the GUI if the signal is not enabled (circuit closed). ANDREWS COMBIfl o...
  • Page 76 March 2022...

This manual is also suitable for:

Combiflo 150/300

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