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andrews COMBIflo 100/300 Installation, Operation And Maintenance Manual

Indirect high ef ndirect 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
Indirect High Effi ciency Boiler & Stainless Steel Storage Water Heater
100/300
150/300
Please read and understand these instructions before commencing installation and leave this manual with the customer for future reference
M6500 Rev B
M7889A

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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 Indirect High Effi ciency Boiler & Stainless Steel Storage Water Heater 100/300 150/300 Please read and understand these instructions before commencing installation and leave this manual with the customer for future reference M6500 Rev B M7889A...
  • Page 2 Technical Parameters 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...

  • 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 DRAFT GB/IE...

  • Page 4: Description Of Appliance

    1.1 DESCRIPTION OF APPLIANCE Th is 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. Th e COMBIfl o range of appliances also features an integrated stainless steel tank and plate heat exchanger for the supply of hot water.

  • 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 DRAFT GB/IE...

  • Page 6: Safety

    2.1 USAGE AND COMPETENCY 2.1.1 IMPROPER USE Th is Andrews Water Heaters product has been designed and manufactured to comply with current Euro- pean standards of safety. However, following an improper use, dangers could arise concerning the safety and life of the user or of other people, or damage could be caused to the appliance or other objects. Th is appliance is designed to be used in a pumped hot water space heating system and potable hot water supply and storage.

  • Page 7: Regulations And Standards

    - IGE/UP/2 - Gas Installation Pipe work, Boosters and Compressors for Industrial and Commercial Premises - IGE/UP/10 - Installation of fl ued gas appliances in industrial and commercial premises. Th ese manufacturer’s notes must not be taken in any way as over-riding statutory obligations. ANDREWS COMBIfl o DRAFT GB/IE...

  • Page 8: Ce Marking

    - Protection requirements (04/108/EG) is only guaranteed when operating the appliance for its correct purpose. Th is 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 DRAFT GB/IE...

  • Page 9: Technical Data

    3.0 TECHNICAL DATA 3.1 GENERAL DIMENSIONS & CONNECTIONS ANDREWS COMBIfl o DRAFT GB/IE...

  • Page 10: Performance Data

    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 DRAFT GB/IE...

  • Page 11: System Schematic

    3.3 SYSTEM SCHEMATIC ANDREWS COMBIfl o DRAFT GB/IE...

  • Page 12: Application Examples

    3.4 APPLICATION EXAMPLES Heating Circuit 1 + Heating Circuit 2 + Heating Circuit 3 (Simple) ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 13 Heating Circuit 1 + Heating Circuit 2 + Heating Circuit 3 (Mixed) ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 14 HC2 Mixer Valve HC3 Mixer Valve Y1 / Y2 Y5 / Y6 Y11 / Y12 B1 10K Temp Sensor B12 10K Temp Sensor B14 10K Temp Sensor QAD36 QAD36 QAD36 (P/N: 5103867) (P/N: 5103867) (P/N: 5103867) ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 15 (P/N: 5138511) Outside Sensor QAC34 (P/N: 5104726) HC1 Pump HC1 Mixer Valve HC2 Pump HC3 Pump Y1 / Y2 B1 10K Temp Sensor QAD36 HC2 Manual HC3 Manual (P/N: 5103867) thermostat thermostat (P/N: 5117503) (P/N: 5117503) ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 16 HC1 + IMMERSION HEATER + BMS ANDREWS WATER HEATERS Immersion Boss 230V 50Hz Contactor HC1 Pump 230V 50Hz Immersion Heater HC1 Manual thermostat (P/N: 5117503) ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 17 BMS & INTERNET CONNECTIONS ANDREWS COMBIfl o DRAFT GB/IE...

  • Page 18: Wiring Diagrams

    3.5 WIRING DIAGRAMS pcb 1 ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 19 2 & 3 ANDREWS COMBIfl o DRAFT GB/IE...

  • Page 20: Sensor Values

    (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 DRAFT GB/IE...

  • Page 21: Installation

    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 DRAFT GB/IE...

  • 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 DRAFT GB/IE...

  • Page 23: New & Existing Heating Systems

    Th is will result in Chloride 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 DRAFT GB/IE...

  • Page 24: Water Connections

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

  • Page 25: Open Vent Design

    Th e 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 DRAFT GB/IE...

  • Page 26: Unvented Design

    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 DRAFT GB/IE...

  • Page 27: Secondary Return Design

    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 DRAFT GB/IE...

  • 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 DRAFT GB/IE...

  • 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 DRAFT GB/IE...

  • Page 30: Flue Systems And Ventilation

    Th e minimum free areas required are as follows:- Low level (inlet) iHE 100 = 376 cm iHE 150 = 560 cm High level (outlet) iHE 100 = 188 cm iHE 150 = 280 cm ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 31 Heater by three degrees. Terminal positions must comply with the requirements detailed in section 4.12.2 4.12.3 VENTILATION REQUIREMENTS (TYPE C & C Where the appliance is installed in a ROOM or COMPARTMENT no additional ventilation is required. Clips every 1000 mm ANDREWS COMBIfl o DRAFT GB/IE...

  • Page 32: Flue Terminal Positions

    R From an adjacent wall to fl ue (vertical only) S From an adjacent opening window (vertical only) 1000 T Adjacent to windows or openings on pitched and fl at roofs U Below windows or opening on pitched roofs 2000 ANDREWS COMBIfl o DRAFT GB/IE...

  • 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 DRAFT GB/IE...

  • Page 34: Gas Connections

    Check for gas tightness (BS. 6891) in pipework to the appliance by connecting a manometer to the inlet pressure 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 DRAFT GB/IE...

  • 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 DRAFT GB/IE...

  • 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 sensor) mixer valve) mixer valve) * Can be freely confi gured ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 37 Th e 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 guide for further details on how to confi gure these modes ANDREWS COMBIfl o DRAFT GB/IE...

  • 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 DRAFT GB/IE...
  • 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 options are recommended: For commissioning and operation of the OZW672 please refer to the Siemens guide accompanying the device. ANDREWS COMBIfl o DRAFT GB/IE...

  • Page 40: Wired Room Units And Outside Sensor

    (about 1.5 metres above the fl oor) See illustration on the following page for guidance on sensor positioning ANDREWS COMBIfl o DRAFT GB/IE...
  • 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. Th e base provides the power for QAA55 and QAA75. When the room units are removed from the base, power is cut off (i.e. the units are out of operation). ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 42 3. Briefl y press the occupancy button. Th e next parameter is selected for setting. 4. Exit service level: - After 8 seconds without activity, the room unit exits the service level automatically. - Briefl y press the operating mode button. ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 43 AGU2.5), the setup of the RGB room sensor, 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 DRAFT GB/IE...

  • Page 44: Filling And Removal Of Air

    1. Ensure that the supplied auto air-vent has been fi tted to the top of the main LLH and the auto air-vent fi t- ted to the fl ow LLH is in place and the caps of both vents have been loosened (approx one turn anticlock- wise). Main LLH auto air-vent Flow LLH auto air vent ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 45 6. Recommended fi ll pressures: Min 0.5 bar, Max 3.5 bar. 7. Check for water leaks inside and outside of the appliance and retighten joints as necessary. 8. Top up inhibitor levels as necessary (see 4.4 for details) ANDREWS COMBIfl o DRAFT GB/IE...

  • Page 46: Commissioning Of Heat Engines

    Siemens OCI700 service tool or the Andrews commisioning tool, available directly from the manufacturer. If neither of these tools are available to the commissioning agent, then the following manual procedure should be used:- 5.2.2 HEAT ENGINE ONE (TOP MOST UNIT) COMMISSIONING...
  • Page 47 CO readings that exceed 200ppm, 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 200ppm, 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 200ppm. If you are experiencing readings that are outside any of these expected values, please fi rst check that your gas analyser is functioning correctly and then contact Andrews Water Heaters on the customer support number on the rear cover of this manual, for advice.

  • Page 50: Frost Protection And Legionella

    • Remind the user that in order to comply to the regulations in force, the appliance has to be inspected and serviced regularly as indicated by the manufacturer. ANDREWS COMBIfl o DRAFT GB/IE...

  • Page 51: Fault Finding

    5.5.2.1 FAULT DISPLAY EXAMPLES Th e 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 DRAFT GB/IE...

  • Page 52: 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 DRAFT GB/IE...
  • Page 53 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 DRAFT GB/IE...
  • Page 54 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 DRAFT GB/IE...

  • Page 55: Removing And Changing Components

    Th e 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 DRAFT GB/IE...
  • Page 56 • 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 DRAFT GB/IE...
  • Page 57 • Carefully pull off the mains connections (pull back locking tab) and ignition cable from the spark generator. • Release the screws holding the spark generator to the bracket (do not fully remove), and remove the spark generator. • Replacement is the reverse. ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 58 • 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 side- ways • Replacement is the reverse. ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 59 • 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 DRAFT GB/IE...
  • Page 60 • After fi ve minutes check the rate and combustion is correct to the table on page 8. Adjust using the throttle 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 DRAFT GB/IE...
  • Page 61 • 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 DRAFT GB/IE...
  • Page 62 • Th e heat exchanger is now only retained by the two side brackets. Releasing the four front screws will enable it to be pulled forwards. Warning this item is heavy - Before releasing the brackets ensure support is available • Replacement is the reverse. ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 63 • 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 DRAFT GB/IE...

  • Page 64: Component Parts List

    AVS74 Graphical User Interface 5142711 On / Off power switch 5142705 Reset switch 5142706 LMS Interface PCB 5142707 COMBIfl o LMS14 PCB 1 5142708 COMBIfl o LMS14 PCB 2 5142709 COMBIfl o LMS14 PCB 3 5142710 ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 65 AGU2.5 clip-in extension 5139793 QAC34 Out-side sensor 5104726 Optional RGB Room sensor 5117803 Optional QAD36 Flow temperature sensor 5103867 Optional QAA55 Programmable room thermostat 5138511 Optional QAA75 Programmable room controller 5117802 Optional Commissioning controller 5141599 ANDREWS COMBIfl o DRAFT GB/IE...

  • Page 66: Component Illustrations

    6.4 COMPONENT ILLUSTRATIONS Fig 7.1 ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 67 6.4 COMPONENT ILLUSTRATIONS (CONTINUED) ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 68 (Q1) Control Heat sensor exchanger pump (Q1) primary pump (Q3) Plate Heat Exchanger 300ltr tank ANDREWS COMBIfl o DRAFT GB/IE...

  • Page 69: 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 DRAFT GB/IE...

  • Page 70: Fault Code Table

    Safety shutdown - Water pressure too low - top up system Input BX, same sensors BX sensor duplicated - check parameters Input BX/extension module, same sensors BX extension module sensor duplicated - check parameters Table 3.0 ANDREWS COMBIfl o DRAFT GB/IE...
  • Page 71 Operating mode button locked - Cannot operate Remote system enable operating. Check to see if link is still in in DHW or Heating mode (No fault displayed) place or controls wired to these terminals are closing this circuit. ANDREWS COMBIfl o DRAFT GB/IE...

This manual is also suitable for:

Combiflo 150/300

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