Instructionsfor Installationand Servicing
Vaillant Combinedappliances for heating and domestichot water
VCW2Ol1 T3 W GC-No.47 04403 VCW2511 T3 W GC-No.47 04405 VCW-sine18 T3 W GC-No.47 O4401
Centralheating Domestichot water
This aoolianceshall be installedin accordancewith the relevant Codesof Practiceby BritishGas or by an authorizedinstaller CORGImember)
These instructions should be left near the gas meter when the installation is completed. Contents 1 lntrcduction P4e- The Vaillant csnbi boiler is a wall-rnqrrH 1.lntroduction 2 natural draught open-flued (or in the case d 2. Construction of aPPliance 2 VCW-sine, room-sealed) boiler with buifr it hot water heater, J. Generalreouirements 4 instantaneous domestic "Technical 4. lnstallation of boiler ^l Outputratings are shown in Dda-. circulation system Water The boiler is designedfor use in a sealedc Commissioningand testing ;\ open vented system with pumped circuldin Assembling ;; 7. ahd includes the instantaneous hot w& of combi heater ,; 8. Servicing sYSIem. q Foultfinding 46 (forseald 10.Short list of ports 61 Circulatingpump, expansion vessel 11.Technicaldata 64 system only), terminal box, control and sdetf devicesare providedwith the appliance. Note to Installers ln hard water areas we recommend the d supply to the appliance is via a scale reducer. 2 Constructionof ApPliance
-24
9 11
23 22 14
18 19 o 21 N 3
o trin I
2 l Fkrcorinection 13 Terminalbox 2 Down draught diverter 14 Switchboard (mainswitch, heating 3 Sensorof overheat cut-off device switch, domestic hot water switch) 4 Mainheatexchanger 15 Domesticheat exchanger 4a Combustion chamber 17 Flowthermostat 5 Main hrmer '18Pressure relief valve 6 Gasgovernor 19 Service cock 7 Flowswitch 20 Gas service cock 8 Differential valve 21 Overflow (optional extra) 9 DC solenoid 22 Push button start 10 Fbwthermometer 23 Push button stop 11 Pump with automaticair vent 24 Pilotburner 12 Pressuregauge 25 Piezounit
\a- l air vent points
o o '6 = o cP 342 Centralizedhot water suPPlY 3 Generalrequirements Part 1 Individualdwellings, 3.1 Related documents Part2 Buildingsother than The installationof the combi boiler must be in dwellings. accordancewith the relevantrequirements of BS 5440 Flues and air suPPlY for the Gas Safety Begulations.),building regula- appliancesof rated input not tions, l.E.E. Regulations,and the byelaws ot ding60 kW (1. and 2. familY the localWater Undertaking. Part1 Flues It should be in accordancealso with any rele- Part2 AirsuPPlY. vant requirementsof the localauthority and the BS5446: 1979 relevani recommendationsof the following Installationof gas hot British Standard Codes of Practice: suppliesfor domestic PurPoses CP 331 Installationof pipes and meters for We liketo drawyourattentiontothefactthd lown gas, connection for the filling or replenishingol a Part 3: Low Pressure installation sealedprimary circuit from a supplypipe is can pipes. ditionalupon a water undertakingseeking aa BS 5376 Selectionand installation obtainingconsentfora relaxationotits Byeh of gas space heating(1 . and 2. family 3 and 8 (1)from the Secretary of State. gases). .) Gas Safety Regulation,1972: Part 2 Boilers of rated inPut not It is the law that all gas appliancesare ins{d exceeding60 kW. by competentpersons in accordancewith t: BS 5449 Central heating for domestic above regulations.Failure to installappliar a , oremrses. correctlybould lead to prosecution.This b L Part 1 Forced circulationhot water your own interest and that of safety to erisG syslems. ihatthe lawis compliedwith.
3.2 Location 3.2.1Vcwqjle (8.F. APP|iance) 3.2.2VCW (O.F. APPliance) The locationdhosen for the combi boiler must The locationchosen for the combi boilernrrsl oermit the provisions of a satisfactory flue permit the provisionof a satisfactoryflue ad ierminal. The location must also provide bdequate air supply. The location must fu adequatespace for servicingand air circulation provide adequate space for servicingard * around the heater. The combi boiler may be circulationaround the appliance. installed in any room, although particular The combi boilermust not be installedin a rqq attention is cjrawnto the requirementsof the containinga bath or shower. In addition,it b l.E.E. Regulationsand, in Scotland, the recommendedthat the combi boilershould rd electricalprovisions of the buildingregulations, be fittedin a bedroom.Where the installationd with respect to the installationof the combi the combi boilerwill be in an unusualposilb\ boilerin a room containinga bath or shower. specialprocedures may be necessaryand BS Wherethe installationof thecombi boilerwill be 5'326:2 and BS 5546give detailed guidanceot in an unusuallocation, special procedures may this aspect.A compartmentused to enclosete be necessaryand BS 5546 and BS 5376 : 2 combi boilermust be designedand construec give detailedguidance on this aspect. specificallyfor this purpose. An existingop- bbard or iompartment may be used provided compartment used to enclose the combi A that it is modifiedfor the purpose. boiler must be designed and constructed specificallyfor this purpose. An existing cup- Details of essential features of cupboard board or iompartment may be used provided compartmentdesign includingairing cupboad that it is modifiedfor the purpose. installationsare given in BS 5376 : 2. Details of essential features of cupboardi compartmentdesign includingairing cupboard instdllationsare given in BS 5376 : 2.
3.3Gas supply 3.3.1Service pipes the availabilityof an adequatesupply of gas. Thelocal gas region should be consulted at the An existingservice pipe must not be usedwit> installationplanning stage in orderto establish out prior consultationwith the localgas regiorl 4 3.3.2 Meters 3.3.3 lnstallation pipes A gas meteris connectedto the servicepipe by Installationpipes should be fittedin accordance the local gas region or a local gas region withCP 331 :3. contractor. Pipework from the meter to the combi boiler An existingmeter should be checkedto ensure must be of a adequatesize. Do not use pipesof that it is capable of passing an additional a smaller size than the combi boiler gas 2.95 ms/h (106 CFH) before the VCW 20 connection. (or 3.38 mslh(122 CFH) beforethe VCW 25 or The complete installationmust be tested for 2.47 melh(89 CFH) beforethe VCW-sine18) is soundnessas describedin the above installed. Code.
3.4 Flue system Detailedrecommendations for fluing are given Flue pipes and fittingsshould be constructed in BS 5440 : 1. Thefollowingnotes are intended from one of the followingmaterials: to give generalguidance. a) Asbestoscement, b) Aluminiumor stainlesssteel, \=i= 3.4.1 VCW-sine (B.F. Appliance) c) Cast-iron acid-resistant vitreous enamel The boiler must be installedso that the flue lined. terminalis exposedto the externalair. lf double-walledflue pipe is used it shouldbe of Terminationshould be on a clear expanse of a type acceptable to British Gas. wall; lf a chimneyis used it preferablyshould be one the terminal being preferably not less than that is composedof or lined with a nonporous 600 mm (2 ft.) awayfrom acorner, a recessora acid-resistant material. (Chimneys lined projecilon. with salt-glazed earthenware pipes are Do not install the terminal: acceptableif the pipes comply with BS 65 and : 1.) A flue pipe a) Within 300 mm (1 ft.) measuredvertically 540 constructedfrom one of the materialsin a) to c) above formthe initial from the bottomof an openablewindow, air should vent,or any other ventilationopening. connection to lined chimneys. Where a is to b) Within 300 mm (1 ft.) above adjacent chimney be usedwhich is not composedof ground level. or lined with a non-porous acid-resistant c) Within 600 mm (2 ft.) of any surfacefacing materialit shouldbe linedwith a stainlesssteel the terminal. flexibleflue liner or any other liner that is of a d) lmmediatelybeneath eaves or a balcony. type acceptableto BritishGas. The internaldia- meter of the liner must not be less than shown Where the lowest part of the termlnal is less in the technicaldata and the number of joints than 2 m (6,6ft.) abovethe levelof any ground, mustbekepttoaminimum. lf thefluelinerisnot balcony, flat roof or place to which people have to be connected directly to the combi boiler access, the terminal must by protected by a draught diveder a flue pipe which is guardof durablematerial. A terminalprotective constructedfrom one of the materialsin a) to c) guard is availableas an optionalextra with the above shouldform the connectionbetween the combi boiler.The air inleVproductsoutlet duct draughtdiverter and flue liner. and the terminalof the boilermust not be closer than 50 mm (2 in.) to combustible material. Before connecting the combi boiler to, or Detailed recommendationson inserting a liner into, a flue that has been Drotectionof previously combustiblematerial are given in BS 5440 : 1. used, the flue must be thoroughly sweptclean of any soot and loose material.lf a plate, plate, 3.4.2VCW (O.F. Appliance) register restrictor damper etc. is fitted in the flue, it must be removed before Detailedrecommendations for fluing are given connectingthe combi boiler to, or insertinga in BS 5440 : 1. The followingnotes are intended liner into,the flue. to give generalguidance. The flue should terminatein accordancewith The cross sectional the flue area of fitted to the the relevant recommendationsgiven in BS combi boiler must be not less than the area of 5440:1, table4. the flue outlet of the appliance.An adapter is suppliedto allowthe fittingof 125 mm steelflue A terminal of a type that has been tested and pipe or 125mm lightasbestos cement flue pipe. found satisfactory by British Gas should be When fitting flue pipes a split socket fittedat the flue outlet. connector must be fitted to ensure easy The point of termination must not be within disconnection of the flue pipe (see page 13 600 mm (2 ft.) of an openablewindow, air vent fig.16). or any other ventilationopening. c effective area of permanent air 3.5 Air supPlY minimum vent(s) is specifiedbelow and is relatedto the for air supply are Detailed recommendations maximumrated heat inputof the unit. given in BS 5440 : 2. The followingnotes are to give generalguidance. intended Appliance cmz in.2 3.5.1 Room or internal space air supply vcw20/1 108 16 vcw25/1 130 20 The room or space in which the boiler is located must have a permanentair vent' This vent must be eitherdirect to the outsideair or to room or internalspace which must The balancedflued combi boiler, VCW-sine, an adiacent'have or internalspace to itself a permanent air vent of at least doesnot require the room i-n" same sizd direct to the outside air. The havea oermanentair vent.
with the room 3.5.2 Cupboard or compartment air supply vents must either communicate or internalspace or be directto outsideair. Where the combi boiler is to be installedin a the permanent cuoboardor compartment,permanent air vents The minimumetfective areas of cupboard or required (for cooling purposesand in the air vents required in the are (Tab. 1) and case 6f open flued appliances also for compartmentare specifiedbelow rated heat inputof combustionand flue dilution)in the cupboardor are ielatedto the niaximum compaftmentat high and low level' These air the unit.
Air vent areas
Pos.of Airfromroom or Airdirectfrom airvents internalspace outside cm2 (inr) cmz , (inr) I 280 {42) 140 (21) High vcw20/1 (25) Level vcw25/1 320 (50) 160 VCW-sine 235 (36,5) 120 (18,5)
560 (84) 280 (42) LOW vcw20/1 (50) Level vcw25i1 640 (100) 320 VCW-sine ,235 (36,5) 120 (18,5)
Tab.1 air vents Both air vents must communicatewith Where cupboard or compartment Note: or internalspace the same room or internalspace or must communichtewith the room must itself have a be both on the same wall to the outside the room or internalspace specifiedin 3.5.1. air. permanentair vent(s)as
3.5.3 Effect of an extract fan combi boilersflue couldoccur when the extract such installations lf there is anv tvpe of extractfan fitted in the fan is in operation.Where in BS 5440.: 1 oremisesthere i6the possibilitythat if adequate occur a spiilagetest as detailed any necessaryactlon iir inlet area from outside is not provided must be carriedout and ipittag" of the products from the open flued taken.
3.6 Water circulation system through roof spaces and ventilated for the water are run Detailed recommendations underfloorsPaces. circulationsystem are given in BS 5376 :2' BS located in accessible 5449 :1 (Jorsmall bore and micro bore central Draininq taps must be permitthe drainingof the whole heatinq svstems) and CP 342- the following oosition-swhich heaterand the hot notes ire of particularimportance. Pipework svstem includingthe combi shouldbe at least not forming pbrt ot the useful heatingsurface water system.Dlaining taps be in accordancewith should belnsulated to help prevent heat loss 1/2 in. nominalsize and and possiblefreezing, particularly where pipes BS 2879. 6 F ,l 3.7 Electrical supply 50 Hz.Fuse rating is 3 A. Wiring external to the combi boiler must Thecombi boiler has to be connecteddirect to be installed in accordance with the l.E.E. the mainselectricity supply using the internal Regulationsand any local regulationswhich terminalbox. apply. Forwiring instructions see paragraph 4.7. The combi boiler is supplied for 22O/24OV, 4 lnstallationof boiler (16 in.) must be availableat the front of the appliance to enable the combi boiler to be 4.1 General servrceo. The combi boiler is to be wall-mountedand a Serviceclearance of 150 mm (6 inches)either verticalflat area of wall is requiredwhich must side is reouired. measureas shown on template- For the open flue type appliancesVCW 2011 This area does not include clearance for and 25/1 an additional clearance is requiredfor installationand servicing. lf the appliance is the flue. The combi boiler is supplied in fitted on a wall of combustible material, the wall 2 cartons,one containingthe boiler,the other should be protected by a sheet of fireproof the installation accessories. An additional \- material. cartoncontaining the terminal/ductassembly is In addition.a minimum clearanceof 400 mm deliveredwith the balancedflued appliance.
o o c o6 >o- FO. (U
vcw20/1 vcw25/1
A 1095mm 1161mm
130mm B 125mm with adaoter
15mm 22mm
D 'l00mm 107mm E- r 1014mm 1080mm
K Electricalmains connection
weight 59 kg 60 kg
) Minimumdistance required to removeexpansion vessel. Installationmay require anotherdistance. Fig.3 Alldimensions inmm 7 ! ; t Fig.4 Alldimensions in mm
4.2 Fluing union (flow of heating Forthe installationof the flueset (wallcase) ot a 1. Compression room sealed-in.t"llation combi boiler, we reter-to rne svstem) cock (flow of heating system) .!-o"t"i" instructions No' 806901 z. S-ervice water connection iniluded with everyflue set. 3. Domestichot 4. Union(gas) 4.3 Connection 5. Gas service cock Cold water connectionwith shut-offvalve pipeworkfor gas and water 6. A oeneral view of 7. Servicecock (returnof heatingsystem) given in fig. 5. coinection is 8. Over flow (optionalextra) The following procedure describes the 9. Pressure relief valve installation. 10. Compression union (return of heating The wall distance(to the finishedwall) of pipe- system) support woit I 4.3.1 lnstallation aids 4.3.1.1Open flued combi boiler Afterfixing the connectinggroup to thewall put the template in positionancl mark posltlonsoI fixingholes. The type of fixing used will dependon the type of wall. I **!**oI 4.3.1.2Room sealed combi boiler After installinqthe terminal/ductassembly, hanothe tempi-ate on the fixing bolts (1 ) anddrill rl I ll the5 holeswith 8 mm(5/16 inches) diameterto fl | )l fit the connectinggroup. Use the alternative fixingholes where necessary. +1- I 4.3.2Domestic cold and hot watel connection - Flush out all loreign matter from the supply pipe before connecting to the connectinggrouP. - Fit the domesticmains water pipe to the riqhthand compression union (2) and the h5twater pipe to the lefthand compression union(3). ln hardwater area the mains supply to union (2)should be via a scalereducer' - bhect domesticwater system for sound- ness. N.B.Thecombi boilerhas amaximumworking oressureof 10 bar. lf water pressure bxceedsthis a pressurereducing valve willhave to befitted to coldwater inlet. 10 {33 Gonnection of heating system Fledirtgsyslem flow and returnshould be in 2. rrtn copper pipe and connectedto the cqrtecting groupas shownin fig. 9. Ftl lhe heatingsystem and test for soundness. I I I t 4.3.4Pressure relief valve and overflow The pressurerelief valve, required for a sealed system,is includedinto the connectinggroup. - Screw in the overflow (4) below the pressurerelief valve into the drain line. (Tobe availableasan optional extra.) 4.4Fitting the appliance Closeservice cocks (5), unscrew union nuts (6) and take off the olive-shapedplastic plugS. Refit union nuts (6) with brass'compr6ssi-on rings (7). Close mainswater service cock (8) *-A-6 I andunscrew the union nutF (9). 4.4.1 Open flued aPPliance Unpack boiler from carton and remove side oarieislas in 8.1'1.),lint arrestor(as in 8'2'2) inO pait ing aids as well as plasticcaps.from the ionneciions. Insertthe appliancewltn tne connection tubes downwards into the com- oiession unionsof the servicecocks and hang it on to the bolts(1)and fasten screws (10)' Fastencompression unions (6) and union nuts ig),using thb attached washers (1 1)' 4.4.2 Balanced f lued aPPliance Unoack boiler from carton and remove side Janels(as in 8.1.1.) and packing aids as wellas blastic baps from the connections.Fit the flue buct (20) irtitntne 2 sheet metal screws (22) to the t;le6copic duct (16) of the terminal/duct assemblY. Insertthe appliancewith the connectiontubes downward iirio the compressionunions of the service cocks and hang it on to the threaded bolts of the wall case (1), fig. 14. Fasten nuts, unions(6, fig. 13)and unionnuts compression 20 21 is, iig. 13) using the attached washers (11,fig.13). 1 Fixingbolts 16 Telescopicduct 19, 22 Sheet metal screw 20 Flue duct Fig.14 2'l Flue bend 12 45 Gcconnection Frtthe gasservice cock (5) to the appliance. Cleil out all foreign matter from the gas s.Dpty pipe before connecting to the service cock! Connectthe gas supply pipe to theservice cock and tighten. F--i tl tl tl ri a 4.6 Flue connection (openflued) Insertflue intothe draughtdiverter after fitting the adapterprovided. A split socket connector must be fitted to ensure easy disconnection of the flue to simplifyremoval of themain heat exchanger. 21. Fluepipe 22. Draughtdiverter 22.aCollarotthe draught diverter 24. Adapter 25. Splitsocketconnector 4.7Electrical connections Vaillantcombi boilers are completelywired. lt is onlynecessary to connectthe electrical mains a andthe room thermostat. Connectto220/240v 50 Hz.electrical sgpply fused 3 A. Warning!Thisappliance must be earthed. Afterremoving the terminal box cover connect themains to theterminal (c) of the appliance in the manner indicatedbelow. A cardboard labelshowing the correctmains connection to the terminalsis in the terminalbox. Please removebefore connecting. Do not connectthe electricalsupply to the pumpterminals (b). Full wiring diagrams for various control schemesare shown intig.21 Io 24. 4.7.1 Connection of the mains cable As shown on the figures the live conductor *nicn is colouredbrown must be connectedto the terminalmarked with a L on the appliance inO to tne tetminalmarked L or colouredred on the Dluq.The neutralwire colouredblue must 6e ioni"ct"O to the terminalmarked with a N on tne aoptianceand to the terminalmarked N oi coioureOblack on the plug' The earthwire colouredqreen and yellow must be connected i" rn" otine two teiminals marked O on the terminalmarked wrth an E @@_a "opiiin"" and to the 1 oi svmbol O or coloured green or green ano plug. lf no room thermostator ..'\L*= vellow on the -j LEf,-l iimer is installbd,-terminal3 and 4 must be linked. @a a. Fuses2 A (delayaction). b. Terminalsfor pump regulating' Fig.18 i- Terminalsfor hpplianceinput connections' 4.7.2-- Connection of Vaillant room thermostat with clock (no' 394) Connectionof room thermostatis made to the terminiri g anO4. lt is recommendedto installa Vaillantroom thermostat (RT) with accelerating resistance. The room thermostat must De inJiiiteo on an inner wall which is influenced neiiner Ov current of air nor by the sun, in the livinq rooin. Duringthe installationof the room therftostatthe manufacturer'sindications must be followed. For the sake of economy and iotfurt the Vaillant combi boiler should be requlated by a room thermostat with icceleiating resiitance. lf the room thermostat is not connected,to operate the heating system ior i"iting purposes'afterthe installation,the ,nit "an bi op6ratedby provisionalapplication oi a OriOgebetween ihe terminals 3 and 4' Wfren tfrE room thermostat is wired in this bridgemust be removed. 4.7.3 PumP control The pump may be controlledin one of three ways (seefig. 20): t SettinqI (as suPPlied) For-use with clock and room thermostat systems. Pump is switched off by clock or room thermostat. Settingll For"use with thermostatic radiator valve svstems. Pump is switched off by clock or gas closes' o'asvalve switih when valve Sz selttingttl Purip runs Permanently and is not affected bY external controls. i 14 1,7, Thcrmostatic radiator valves l$rere TRVs and a clock are used the ilibfrirg side of the clock is connected betreen teminals 3 and 4. lYhereno clockis useda wire bridgemust be insertedbetween lerminals 3 and 4. Setthe pumpcontrol to positionll. VCW-Terminal RANDALL TimeSwitch 103 Do not link terminal3 & 6 VAILLANT Roomthermostat VBT378 N Mains L Supply 0 I 24OV/5OHz Fig.21 VCW-Terminal SWITCHMASTER300 Time Switch a REMOVE O 1) LinkN and 2 VAILLANT 2) Link L and:4 Roomthermostat VRT378 N Mains L Supply 0 3 24OVlsOHz 15 HORSTMANN 125 COFONET Time Switch Do not link terminals Land5! VAILLANT N Foomlhetmostat t.in" vRT 3 78 L SuPPIY 3 J 2r0v/50H2 o l':-' Fig.23 O VAILLANT Roomthermostat N Mains VRT 378 L SUPPIY B 0 + 24ovl5oHz 16 E -9- 6=O E;E 9p5 ; "9=i a E$s E a o .o l lt^ I (, a ol CD cl 988- c x*'t lo I :oo (o 3 o(g I F I b i i p o c o o a? o o 3 o ' o = ; ",1 EY r() AI .st, tt E o o o '=c 15 14 13 '12 21 n 23 11 24 10 9 25 I 77 7 26 6 5 70 30 71 2A 73 54 n 5:l 31 58 /-ffi 61 7A 46 1 0t[|il[[|ll 32 Fig.26 16 sensorof overheatcut-off device 1 service cock 17 main heat excnanger flow switch 3 ventingscrew 4 thermostaticelement 18 air 19 expansionvesset 5 gas inlet main burner 6 automaticvalve 20 gas governor 7 pilotadiustment screw 21 .. 22 mainburner adjustment screw I switch box/FFD double-stagemain burnervalve 9 oush button start i3 venturi 10 pilotvalve 24 differentialvalve 11 push buttonstop 25 26 DC solenoid 12 thermo-magnet expansionvessel pressurecontrol 13 micro switch i8 29 pump 14 thermo-couple 15 pilotburner 18 -'_-43 N--.a.-:.*. 58 micro-switchhot water water 59 watersedlon . 3?:li"#3[?t!l3ll o"'"""'ic 60 coldwater inlel heatingcircutr 61 watergovernor. 32 outlel 39 mainswitch 63 hotwater 41 terminal i tlo"o"* 3e!3il'J3-:Y':ilvarcr switch X3 rn"rto""' 70 electroniccontrol i 71 NTCresistor 1?"1.1H,$3#3f;'ftL *"*"' 78 systembypass 79 relaY $i[#s$:rrtt:"'micro-switcnt. 53 54 micro'switcnll 19 5 Watercirculating system 5.1 General are unavoidablethe pipesshould rise upwards The combi boiler is suitable for use on most towards a vent point. microboresystems. miniboreand For qeneral quidance reference should It is recommendedto use copper tubing to BS be mide to ihe British Gas publication 2871 :1for water carryingPiPework. - MATERIAL AND INSTALLATION The use of horizontal pipe runs should be SPECIFICATIONS FOR DOMESTIC -, B avoidedwherever possible in order to prevent CENTRALHEATING AND HOTWATER air collectingin the system. lf horizontalruns and to BS 5376:2 and BS 5449:1. 5.1.1Single PiPe sYstem The heat emittersare installedon a closed circuit.The necessarywater quantity for every heatemitter (radiator) must be ensured.This can be done for instanceby using suction fittinosin the return connection of the radiators. The-radiatorsizes shall be calculatedon the basisof temperaturedistribution around the circuit. Fig.28 5.1.2Two-pipe system The radiatorsare installedparallel and the flow temperaturetherefore is the same for every radiator. Typicalcentral heating installation are shownin the followingfigures. FillingPoint NOTE: 5.2 to 5.5 are applicableto both open and sealedsystems. N.B. The primaryfilling point may be placedat any convenientpoint on the circuit. Fig.29 20 S2Gontols Vdilt cofiti bcilers are ready for connecting oleebcLft:d mains. W$Gn conhds (24OV) may be connected as sfwn h figures 21 to 24. 53 lrolating valves The +dianoe shall be installed with isolatinq dws (service cocks) as described unde-r 4-3_3. 5.'tGirculating pump The cirolating pump is included into the combi boiler. The remaining conveying capacity can betaken from the diagram. SssYstem by-pass A system by-pass is included into the combi bdler. 800 1000 1200 14c,0 1600 L/h 176 220 264 308 352 cPH 5.6 Openvented system lf it is requiredto usethe combiheater in ooen systemsit is possibleto do so without'anv modification to the combi heater. W6 recommendto fit the expansionpipe (2) at the isofationvalve (no. 7,tig. 12)where normallv the pressurerelief valve is fitted.The relevani BritishStandards and Codes of Practiceas well a: otl.gr requirementsinvolved (see also 3.1) shouldbe strictlyobserved. Minstatic head: 0.15 bar (5'water) Maxstatic head:2.0 bar (67'water) see BS5449 clause 24.1 2 expansionpipe 3 expansioncistern 7 overflowpipe Fig.31 21 5.7Sealed systems Sealed systemsdo not requireleed and exDansioncisterns, open vents etc' only gooo ouitiWraOiator valve's and fittingsshould be Jsedin orderto preventexcessive detrlmenlal topping-uP. 5.7.1Pressure lelief valve This is requiredon all sealedsystems and is connected'asshown in 4'3.4' 5.7.2Pressure gauge Thisis factory fitted to theboiler and shows the pressurein thePrimary circuit. 3 5.7.3Expansion vessel A 15 litresexpansion vessel is incorporated into ihe combib6iler suitable for a sealedheating- iuit". with a maximumwater contents of 260litres (57.2 lmP. galls') lf thenominal capacity of the built-in expansion vesselis not sufficientfor the heatingsys,tem. itor-instancein caseof modernizationof old iioen Jvstems)an additionalexpansion ve-ssel cin Oeinstatt6d to the sideconnection of the ieturn service cock in connectionwith the pressurerelief valve. Fig.32 5.7.4Filling and makeuP 5.7.5 Pipework supported,shall shouldbe filledwith watervia a All oioeworkshall be securely The svstem be concealedwhere possible' seoar6telilling point fitted at a convenientpointrun'n'eatlyand on' the neati-nbcircuit. Where local Water Authority Regulationallows, a temporary connectionto-the mainsmay b,eused' The connectionmust be removeclwhen lllllngls completed. Where local Water Authority Reqirlation does not allow temporary corinection,a sealedsystem filler pump with breaktank must be used. The heating system witt not be filled automaticallyfrom the domesticside. ln principle,sealed systems do not require waier mat 22 6 Cornmissioningand testing 6, 1 El€ctrical installation r-e,'rinary electricalsysiem checksto ensure +€sflcal safety shall be carried out by a :r,mpetent person. Those checks are outliired r tne INSTRUCTIONSFOR BR|T|SH GAS IiIULTIMETER. 6.2 Gas installation Tne whole of the gas installation,includinq the reter. should be inspected and testej for soundnessand purged in accordancewith the iecommendationsof Cp 331 : 3. t 6.3 Water circulation system The whole oJthe systemshould be flushedout wtrnDotn cotd and hot water. Ensureall valves are open. With the combi boilerfitted, the systemshould be fiiled and air locks cteared.V6nt tnJOoifei throughthe 4 vent pointsshown ln tiq. iand'2. Loosenthe black cap on the automaiic -z air vent oy 1 turns. Vent all heat emittersand check for.water soundness.On a sealed svstem fiti untilthe pressuregauge registerst.s iraiizr.S PSI). (The system should be filled with water either from a sealed system filler pump with a break La_lK.or by a method of filling given in BS 5376 : 2, appendixA.) Checkoperation of safetyvalve. Release water Tromrne systemuntil the initialsystem pressure oL.-t,zoat ts atatned, taking into account anv otnerence.in height between the pressur6 gauge and rhe point at which the higtiestheat Fig.33 emtnerts connected_ 6.4 Lighting the combi boiter t The first lightingof the applianceshall be done oy a quatttiedfitteronly. He shallalso give clear verbat instructions to the user on how to operatethe combi boiler,controls and systemi generally.Light the combi "lnstructionsboiler as described separatelyin the for use,,. 6.4,1 Gas soundness Test for gas soundness around boiler qas components using sense of smell and l6ak detectionfluid. 6.4.2 Main burner pressure Pull off the plugof the NTC-resistorand test the matn Durner pressure at the main burnei pressuretest point. 23 6.4.2.1Nominal heating inPut Thepressure must be asfollows: intetbressure:20mbar (8.08 in' WG) mainburner pressure (cold and hot): vcw 2011 9.0mbar (3.61 in. WG) vcw 2511 9.0mbar (3.61 in. WG) VCW-sine18 10.6mbar (4.26 in. wG) The apolianceis regulatedat factoryto the .b'ti"5i neating influt. Thereforeit is not n"lJ""urv to a[6r thbsetting of .input or output "itne g"d gouernorduring installation' 1 pilotadiustment screw 2 pilotgas filter 3 DCsolenoid testPoint + mainburner Pressure B 5 gasgovenor 6 blockingPlate 7 inLipti.irte testpoint (near rear plate) 6.4.5Flow thermostat 6.4.3Flue all automatic no spillageof products,of Checkthe flow thermostatand Checkthat there is satisfactorily'Readjust fromthe down draught diverter by Jontiofsare operating JomOustion to appropriatesettings. carryinqa spillagetest as detalleoIn t:D controls i r. only to open{lued il6' thppiicaote In Watersoundness aooliances.)Check appearance ol llames 6.5 thatihereis adequateair for Allow the water system to reach maximum lii,irl"-"iihrtish for water LturitLn, checkalso as outlined under 3'5'3 woif your senticing company' instructions Please contact 6.6User's nearestVaillint office oryour local gas the userfor Vo-u-r Handthe instructionsfor use to region, l"T"niio"unO instruct in the safeoperation.of ii. aooriince. Advise the user of the oi"cauiibns necessaryto preventdamage to ihe svstemand to the buildingif th-esystem JoLJ'not remainoperative during frost con- ditions. Note: Leave installation and servicing instructionsat the meter' For continued efficient and safe operation, "iirt-viiiii"ni ippliance should be serviced o qualified o liLaiion"e a'vearbv a servicing N = company' o re-comm.ended It is important and strongly o that ariangementsare made for a -!44!!!!9 ilt cA-sr6ereLtwith a qualified servicing ififfiv to ensure regular servicing' Fig.35 24 7 Assembling 0 ieotace the plug to the NTC (Negative :ernperature ()= Coefficient) resistor before a :ssembling. 7.1Lint arrestor(open flued appliance) Tofit the lint arrestor hang it into the front side of thelower retaining frame and clip it againstthe appilance. 7.2 Side panels Push the 2 side panelsfrom the front onto the boilerand screwto the upperand lowerframes with two pairs of captive slotted screws. lf the door isre^quired to open from the right see section7.6. +-o = o Fig.38 25 7.3 Screen Plate Positionthe left hand edge of the screenplate unOertne sidepanel. Press the slideunder the eJoeot tne riqhthand side panel and align with the-slotsin the screenplate. Secure the screen otit" *itn 3 screws as indicated in fig 39' ileolace the thermostatknob' 7.4 Front Panel Press the front panel including the grey enameledcentre sbctiononto the boiler'the 4 boltsengage in the spring-boltedsupports' 7.5 Door The door supports are attached at the right hand side panelof the appliance(door opening I from the left).The door is fittedas follows:place the door into the uppersupport and fix to lower supportwith the hingescrew. 26 - 6 Changing door attachment -r€ roor can also be fitted to open from the -i:--. as describedin the following:Changethe -rc,er.and the lowerdoor supportfrom the right -,ar'. to the left hand side panel of the :E€} an@. 7.7 Stickers Stickon - instructionssheet afterfilling in - serialno., - test point pressureand - date of commissioning - wiringdiagram to the inner side of the door as shown on fio.43. 8. Servicingof combi boiler $ The combiboiler should be servicedat least - oncea year.A servicecontract may be agreecl with BRITISH GAS or Your CORGI INSTALLER. @ e a-]r*Lrz I \,{\ 8.1Turning off the combiboiler To servicethe combi boiler @__ ta, - Switchoff electricalsupply (1 , tig.44). - Turnoff gasservice cock (3, fig. 44), boiler isolatingvalves (4, tig. 44) and cold water shut-offvalve (5, tig. 44). 8.1.1Removing outer case (fig.44) Removedoor by unscrewinghinge pin (b) and oullinqdoor out and down. Removeupper banei Oy pullingoutwards. Remove gauge 'screwjlanel bir iemovingboiler thermostatknob' over rockei switchesand loosening screws(c) andsliding right hand panel to the left. Removeside panelsby unscrewingtop and buttomscrews (d) to clearinternal clips and then pullingpanels outwards and off' In the case of the balancedflued combi boiler VCW-sineremove the 4 screwsand washers (A) to removecombustion chamber case as {eir'ry shownin fig.45. t 8.1.2 Drainingthe aPPliance (fig.44 and 46) When necessary,the appliancemay be drained as follows. - Openair vent (18, fig. 46) . - Drain appliance through draln nlpple (tr, fig.46). - D-raindomestic heat exchanger via drain screw (C, fig. 46) as well as pressure relief vdlve (D, fig. 46) at the lower part of the water section. 8.2 Cleaning of burner and lint arrestor 8.2.1Cleaning of burner L 8.2.1.1Balanced llued appliances Removethe burnerby unscrewingthe retaining unionnut (E), the pilotairfilter (F), take care not to lose the pilot inlector.Remove the thermo couple by pullingdown and taking off the high ten6ionlead from the ignitionelectrode. 28 l,lrcrer the retainingscrews (T) and remove trcs. Cileanbumers, injectorsnozzles and il certbly with a light brushor a vacuum CEE' . Fbsenble in reverseorder, replacingthe m-r bumergasket if necessary. Fig.48 82.1.2 Open llued appliance Remove bumers by levering off burner bar with a screwdriver. Remove thermo-couple probe by pulling downwards from pilot assembly so that probe disengaged from circlip. Remove pilot assembly.by unscrewing screw (F). Remove burner bar by unscrewing nut (E). Cleanburners and injectors with a lightbrush or vacuumcleaner. Reassemble in reverseorder, replacingmain burner gasket if necessary. 29 8.2.2Cleaning of lint arrestor (openflued aPPliances) Removethe lintarrestor by pullingdownward the partwhich is nearthe connectionsof the appliance. Cleanwith the light brush or a vacuumcleaner. Reassemblein reverseorder. 8.3 Cleaning of main heat exchanger 8.3.1 Balanced flued aPPliances Removeburner as under8.2.1 .1 . Slackenthe 2 screwsholding the flue hood and slidehood up as far as possible. Remove sensor (3) of overheat cut-off device from pocket on left hand side of heat exchanger. Undo union nuts (G) on heat exchangerunions and slackenlocking nuts (H) abovethem. Removeheat exchanger. Clean heating body especially fins carefully with hot waier, detergents and brush. lf necessary descale with propriety descaling aqent. Do not bend the fins. lf necessary, st-raightencarefully with screwdriver. 8.3.2 Open flued aPPliance Remove burner assembly as under 82.1 .2. Slackensplit collar. Slacken the 2 screws holding the draught diverterand slide draughtdiverter up as far as possible. Remove sensor (3) of the overheat but-offdevice from the pocketon left hand side L of the heat exchanger.Undo union nuts (G) on the heatexchanger unions and slackinglocking nuts (H) abovethem. Removeheat exchanger' clean heatingbody and especiallyfins carefully with hot water, detergent and brush. lf necessary,descale with proprietarydescaling aoent. Do not bend the fins, if necessary st"raightencaref ully with screwdriver. 30 -:_Tove -a-c the venturitube situated in the riqht_ connectionof the heatingO"Ov.b'nZci :,:.e and - -gcessary.o-ring,clean bore and-repla6" ;_*;; =;lp9emble ..in reverse oroer, ensurino A:shers fittedin heat "".n",ig"i'r;;;X : - J rlue .are ductengaged in spigot in flr; 6rrn*;;;i 8.4Descaling of domesticheat exchanger 111:l]r_etcessarytodescatethedomestic-heat excnangerremove the tl .1"_.-:y'qsaus""nd t-n"',i:",ru i:Ji:?"T; -nscrewingthe 2 tubingnuts. For 6et-tei;;;";i :o the connections.reriove the b;;;;e;;fi;; =i:"^ p^y.unscrewing tne S retatning;;;ily the 3 u.nionnuts (K) -o_.1?I--qy9rarn lng_ "io-ir,"'"2 screws(l). Descaleb,jr".ti" rlt"? :11e_:?y ptoryetary descating agents anO rinl-e arerwardswith clean water. 3ea:semble in reverse oroer /yashers. using new 8.5 Cleaning of water section the 'nrernat..I?_-l"Toy.q. water section unscrew the : (N) and the external- (M)";"i;; connectionsand loosenthe screw (L). i:^,,!:tl ":tess to theconnections unscrew :ne towerretaining frame. Open the water section.Clean the water filter (O) or replace,if necessary'Check diaphragm tpj anO water governor (61), replace, if necessary. Reassemble in reverse order using new washers. Where stuffinggland needs replacingfit new too to water section,incorporating new stuffing box. 8.6Maintenance of differentialvalve Mark and disconnectthe two unions and unscrewthe three retaining screws (Q). Ooen differential valve and clean. Check dihohraom and replace, if necessary.Check eaiv ruininq pin of diaphragmdisc in stuffing box. In casebi replacementof the stuffingbox' it is recommendableto replacealso diaphragm disc. Lubricatepin with suitablegrease. Mark and disconnectthe two controllines and clean by blowingthrough. Reassemblein reverseorder. Jt- . Fig.58 32 E-7Eryansion vessel (sealedheating system onlY) lnec* internalpressure of expansionvessel *nir*r shouldbe 0,7 to 0,9 bar' if heating srstemof applianceis withoutpressure (black :'al of build-inpressure gauge at 0). Refillwith ar pump,if necessary. i{:.--ti f5f I (l_ iI 8.8Final tests I o 8.8.1Final test heatingsystem tf o Closeall drain screws and nipples and open the 3 servicecocks to refillthe appliance.lf a sealed O svstem ensure the pressure is 1.2 bar a-ccordingto 6.3. Switchon electricity,turn on qasand start the applianceas outlinedon the ;tickerat the inner side of the f ront door. Check flame failuredevice for correctfunctioning. Checkthe pilotflame and adjust with the pilot rate adluster (7) so that there are three seoarateflames. lf the flame profileis one larqe,loose flame, increase gas rate until3 seiarateflames develop, as shownin fig.60a' Replacepilot jet if necessary. Checkthe appliance for soundness. Check all controlsfor correct functioning' reassembleouter casing of applianceas under7. 8.8.2Final test electricalsystem Check - earthcontinuity polarity s resistanceto earth accordingto INSTRUCTIONSFOR BBITISH GAS MULTIMETER. 8.9 Change of Pilot iet Disconnectthe pilottube fromthe pilot'Change pilotjet and washerand reassemblein reverse ordbr. In case of an open-fluedappliance remove the pilot assembly by unscrewing the retaining bcrew.Changb the pilotjet and reassemblein reverse order. Check connectionsfor gas soundness. 8.10 Change of thermocouple Disconnectthe retainingnut (R) and pull the thermocoupleout of the thermocouplesupport. Insert the new thermocouple fully into the support. (ln case of VCW-sine seal the thermolead into the bottom of the chamber plate by a specialrubber washer). Connect the retainingnut. 8.'l1 Change of sPark electrode (VCW-sineonly) Pull off the high voltage lead, remove the retainingscrew (S), removethe sparkelectrode and replace with the new electrode. Reassemblein reverseorder, ensuring that the sparkgap fromthe electrodeto the flameshield is 3 m;, takingcare notto overtightenthe f ixing ,,n[;5-o j screw. 8.12 Change of NTC (negative temperature coefficient) Plobe Disconnect the AMP plug and unscrew the NTC probe. Reassemblein reverseorder' 8.13 Change of automatic air vent Drainthe applianceas under8'1 and 8.1.2. \, Unscrew the automatic air vent by hand. Reassemble in reverse order, screwing the automaticair vent in bY hand onlY. Open the lockingcap (LC) of the automaticair vent by 1-2 turns. 34 |llf Change of flow switch or parts t-1f.1 Electrical isolation botde the appliance from the el6ctrical mains. Pr.fl off the plug (S1) by shifting the retaining Egu6 (S2) top and bottom to the side. 8.14.1.1Ghange of flow switch mirco switches Sorinqoff the protectivecover (SG).Unscrew (S4 or (S8),take otf microswitch and remove the AMPplugs. Reassemblein reverseorder. Adjust the actuatinglever as outlinedunder 8.14.2.' 1. 8.14.2Removal ol completeflow switch Drainthe appliance as under8.1 and 8.1.2. Removethe 4 unions(S3) and the 2 screws (S4). Pult off the AMP tag (S5) of the NTC resistor. 8.14.2.1Change of flow switch stuffing box Remove complete flow switch as in 8.14.2. Unscrewretaining screw (S9) and take off the micro switch assembly. Unscrew adiustment nut (S10), remove lever assembly, remove 3 screws securing top cover, unscrew stuffing box, remove both rubber seals and fit new seals, ensuring washer is fitted between the seals. Reassemblein reverseorder and adiust lever assembly of the cold flow switch as follows: Turn down the adjustmentnut (S10) slowlyuntil micro switch closes the redto brown circuitand makeone morecomplete turn down. 8.14.2.2Change of thermostatic element Unscrew the 3 retainingscrews (S11) and remove the housing (S12). Reassemblein reverseorder, using new washers. 8.14.2.3Changing internalseals Removehousing as in 8.14.2.2. Bemoveseals R1 and R2 and replacewith new ones. Do not use any jointingcompound or grease. 8.14.3Reassembling Reassemble in reverse order, using new wasners. \" Check - earth continuity - PolaritY - resistanceto earth accordingto INSTRUCTIONSFOR BRITISH GAS MULTIMETER. Note: positionof notcheson plug as shown. .to Af 5 Change ot piezo igniter (VCW-sine only) Elisconneclthe high voltage lead (pl) from the i.d bolt. Removethe retaining screw (p2) and remove the unit by springing the bracket. Reassemble in reverse onier, ensuring that krcding dimple in the bracket aligns wiih the dd in the piezo unit. fr=b4 8.16 Change of DC solenoid lsolate the appliance from the electrical mains. llolg.coloy.r code and puil off the AMp ptugs (Dl) from the micro switch as weil as the'Alrip dugs (D2) from the DC solenoid socket. Loosen the 2 retaining screws (Dg). Beassemble in reverse ordel. Check - earth continuity - polarity - resistance to earth a€cordingto INSTRUCTIONSFOR BR|T|SH GAS MULTIMETER. 8.17Change of DCsolenoid micro switch lsolatethe appliancefrom the electricalmains. Notethe colour code and pull off the AMp oluoi (Ml). Unscrewthe 2 retaining- screws iMi;. Reassemblein reverseorder. Check - earthcontinuity - polarity - resistanceto earth qcggrdingto TNSTRUCTTONSFoR BRtTtsH GASMULTIMETER. l l ri i 8.18Ghange ot pump 8.18.1Change of completepump Drainthe appliance as under8.'l and8.1.2. lsolatethe appliance from the electrical mains. Openthe terminalbox of the pump.Note the colourcode of wiringand disconnectpump connectioncable. Unscrewthe automaticair vent(Pl ) by hand. Markand disconnect the 2 controllines of the automaticvalve by unscrewingthe tubing nuts (P2). Loosenthe 2 pump unions(P3) and unscrewthe bracketfixing screw (P4) and the unionnut (P5)at the righthand connection to themain heat exchanger. 8.18.1.1Open flued boiler Take otf connection to main heat exchanger together with the pump as shown on fig. 75. Reassemble in reverse order, using new washerat the righthand connection to the maln heat exchanger. Screw in the automaticair vent by hand only. Check - earth continuity - polarity - resistance to earth according to INSTRUCTIONSFOR BRITISH GAS MULTIMETER. 8.18.1.2Balanced flued boiler Unscrewthe upperpump union(P3) and spring off the pump as shownin fig.76. Reassemblein 5. reverse order, using new washer at the right hand connectionto the main heat exchanger. Screw in the automaticair vent by hand only. Check - earth continuity - PolaritY - resistance to earth accordingto INSTRUCTIONSFOR BRITISH GAS MULTIMETER. 38 8-18.2 Changeof pump headonty Drain theappliance as under8.1 and g.1.2. lsolatethe appliancefrom the electrical t-lpenthe mains. terminalbox of the prmp. fVoie ggroyrcode of it-e the wirinsano'oisc[nn6ci .jr,L.',iiii! p:llp,_ connecrioncabie. un.,jr"* L"l:ll,lSscrews (p6) ano p.urr otr p-ump.ijE"o] lHrJvJisy*siEb n^eassemble$":F:Ti_{{t,yiHl3lflin reverse order.Ta-ke;;;not to oamagethe packing ring. Check - earlhcontinuitv - polarity _ .. resistanceto earth 3iT'fl0flr,'#PTRUcT|oNSFoRBRrflsH 0 8.19Change of gassection $H:3}lFift?:dif"tj3,.iil?i,i!:ffi"," discorin ectins tn 6..i ilioii' i,fi 3i :fi:.{li"J bytoosenins tne ) JJ i6fi"'o e ieiainiis;;""; 8.19.1Batanced flued appliance ffilr i""Jl:;"J:TiH"","#J:"{t?ilpirotassembrv 8.19-2Open flued appliance thepitot *ruy: suppon.byunscrewinq the l"_r3ll'.19screw (G3)'and ihe ,;i;.'fi;;; ihe a reiainiii' (\rz+r,lAli'9y;^l"movereptace valve #;;: seating, springi ;t". ;; fiffi3,l",3"assembleinrev"'i" oio"i ,lsin'd Checkconnections for gas sounctness. 8.20Change of gas governor \| 8.20.1Balanced flued appliance gas l-l:lgy" sectionas in 8.19 and 8.19.1. unscrew the 4 retaininc 3.'-T?r." i;;""; ###1,3ffi _($3ln *3 I";l???rTrcheck c6nne"ii"""'iJi,'i!t 8.20.2 Open flued appfiance the, main ,T:fy: burner as uncter 8.2.1.2.- y_1s_9r9*,tle retaining . 'orOer,screws ?d;;:.iJ# .l?^1.j9r91"in reverse wasners,if necessarv. using Checkconnections forgas soundness. 8.21 Change of pilot gas filter Removepilot gas linefrom the pilotgas filterby disconnectingthe union nut (G6). Unscrewthe pilotgas filterfrom the gas section. Reassemble in reverse order, using suitable sealingcompound sparingly. Check connectionsfor gas soundness. 8.22 Change of automatic valve stuffing box Disconnectthe differentialvalve as under 8.6. Control lines remain connected.Unscrew the stuffing box (G7), taking care not to bend the oin. Reasemble in reverse order. usino new wasner. Checkconnections for gas soundness. 8.23 Change of switch box lsolatethe appliancefrom the electricalmains. Markthe pilotlines, disconnect the tubingnuts v and removeoilot lines. Pull the thermocoupleout of the pilot burner assemblyand unscrewthe retainingunion nut (82) from the switchbox. Remove the 2 retainingscrews (Bl) and pull out the switchbox. Notethe colourcodes of the wiring and pull the AMP plugs from the micro switches. Reassemblein reverseorder. Check - earth continuity - polarity - resistanceto earth accordingto INSTRUCTIONSFOR BRITISH GAS MULTIMETER. Checkconnections for gas soundness. 40 valve stuffing box 8.24 Change of FFD ""0 i:Hl""ls33? ffi:t'ru1"1'm#,lx;l*:w',?::#3:g:ti and rePrace bYa order' Reassemblein reverse Check - earthcontinuity - PSlflillset:f,S,l,,o" BR,''H a"ft'$it'''-+?JU"JF'"-gassoundness' 6nJ"n*nn""'ions for Fig.83 L {, buttons 8.25Change of FFDPush B3 asoutlinedunder 8'23' ""t""" "" t*itch box (ffi) andpulloutthe push llm; io"r.ingr.ing buttonto the tront' order' "A rtb Reassemblein reverse Check - earth.continuity - polarlry b'ln-s+4"t3;'gKs """.rdi[ FoRBRrrrsH 6nsvuirtuEren' gassoundness' 6n""n "onn""tionsfor Fig.84 ol valve 8'26 Change Pilot (85) (84)and p9l! gut spring Unscrewtn. ofuq -€f b t F ;:flJfl:iin[i'f,lst;'igslas':n?"1"J'::newwasher' 6io"t' utinga l. Ynllli gassoundness' Checxconiections for 8.27 Change of thermo-magnet Removethe switchbox as outlinedunder 8.23. .- Removemicro-switch assembly by unscrewing 3 <88 rig.e6 8.28 To open the control box lsolatethe appliancefrom the electricalmains. Open the main terminal box by removingthe retaining screw (C1).Remove the four retainingscrews (C2). Lift up the switch box and pull out slowly the control box cover complete with the switch board, printed circuit and terminal board. Pull off the multiple plugs from the printed circuit. Reassemblethe box in reverse order. When replacing the screws, position the 2 star washersdiagonally to the screws. 8.29 Change of main swilch board Take off the switch board as outlined under 8.28. Disconnect the mains cable from the terminals.Unscrew the 2 retainingscrews (C3) b and removethe p.c.b.with the mainswitch from the crontrolbox cover. Reassemblein reverseorder. Check - earth continuity - polarity - resistanceto earth accordingto INSTRUCTIONSFOR BRITISH ,z-4. GAS MULTIMETER, "v4-r( t- Fig.BB 42 8.30Change of micro-switchesof water section Opencontrol box as in8.28 and remove switch boxas in 8.23.Remove the adjustmentscrew (C5) and take off the microswitchassembly. PulloffAMP plugs (C4). Reassemblein reverseorder. Check - earthcontinuity - PolaritY - resistancelo earth accordingto INSTRUCTIONSFOR BRITISH GASMULTIMETER. o 8.31Change of overheatcut-off device Openthe control box as in 8.28and remove the switchbox as in 8.23. Pulloff the 2 plugs(CG) and the earthlead, removethe saddleclip (C7),pull the sensor (3, fig. 52) out of the main heat exchanger. Unsciewthe 2 retainingscrews (C8), release grommetfrom box and removecut-off device. Reassemblein reverseorder. Check - earthcontinuity - Polarity - resistanceto earth accordingto INSTRUCTIONSFOR BRITISH GASMULTIMETER. Checkconnections for gas soundness. 8.32Change of electronic P'c.b' Openthe controlbox as outlinedunder 8.28. L Uirscrewthe retainingscrew (C9) on the left ) rt handside of the controlbox. P.c.b. is heldon key-holeslot, pull p.c.b. forward and to the right.Pull off multiplug and white lead. Reassemblein reverseorder and ensurethe p.c.b.is locatedon the lefthand side of plastic peg. Check - earthcontinuity - polarity - resistanceto earth accordingto INSTRUCTIONSFOR BRITISH GASMULTIMETER. 8.33Ghange of expansionvessel 8.33.1Domestic water side Disconnectthe tubing nut (W1), unscrew bracketsecuring screw and remove expansion vesselcomplete with bracket.Unscrew vessel from bracket.Reassemble with new domestic waterexpansion vessel in reverseorder. 8.33.2Heating system open flued appliances Disconnectthe flue at splitcollar. Remove 2 screwsand nuts,securing the upperretaining frame.Lift rear of frame clear of side frames and rest it on top of draughtdiverter. Remove screwssecuring draught diverter and remove togetherwith upperretaining frame. Remove draughtdiverter retaining frame by removing the 2 retainingscrews. Undo the unionnut \_) (W3),move the expansion vessel up and take it off. Reassemblein reverseorder, taking care thatthe expansionvessel is correctlyfixed into the2 supports.Use new washer, if necessary. 8.33.3Heating system balancedflued appliance lsolateelectrical mains and removemains cable.Close off water and gas servicecocks anddrain the appliance as outlinedin 8.1.2. Disconnectflow and return connectionsat compressionjoints on top of service cock. Disconnectgas connectionat compression joint on top of gas cock.Disconnect domestic hotand cold connections on diaphragmbody. Slacken locking nuts on flow and return connections.Remove nuts from bolts (1 in fig. 14) on terminal/ductassembly Rerirove boilerfrom wall. Disconnectsleeve nut (W3) and removeexpansion vessel. Reassemble in reverseorder, taking care that the expansion vesselis correctlyfixed to the 2 supports. : 44 8.34 Change ol thermometer Pull the temperature sensor (U3) out of the sensor tube. Press the 2 tongues into the thermometerand pull it out to the front side' Reassemblein reverseorder. ) t 8.35 Change of manometer Disconnectthe tubing nut (U1) ot the control line and removethe fixing nut (U2). Reassemblein reverseorder. ffi\v wA 8.36Change ol systembYPass Close off flow and return servicecocks and ^ drainboiler as outlined in 8.1.2' b t Unscrewthe 2 union nuts (V) and remove valve.Unscrew the 3 screwsholding the top ol the valve. Renew diaphragmor spring as necessary.Do not movespring adjusting nut' Reassemblein reverseorder, using new wasners. S 9 FaultFinding 9.1 Sheet 1: Check of Flame Failure Device and Thermocouple b rsgas pressure Push green button available? and light Pilot. Can Pilot be lit? De-aeratePilot Gas Pipe by unscrewing ls Pilot Pilot Adlustmdnt Gas Pipe Screw. de-aerated? Checkor clean,if necessary,Pilot Gas Filterand Pilot Jet. CheckPilot flame correct size.Check Thermo' Tip isclean. Check Dositionedin flame. Recitify any fault. 46 - Releas€:greenbutton DaesPitot afterabout Flame re-main 10seconds. z Adiustment\ GheckThermocouple ot PilotFlame and Vohage(min. 15 mV DC). Themocouple (Open circuit). Voltage satisfactory? i 9.2 Sheet 2: Check Electricity Supply IMPORTANT:The preliminaryElectrical System Checks as containedin the B.G.C.multimeter in- structionbook are the first electricalchecks lo be canied out duringa fault findingprocedure. On completionof the service/faultfinding task which has requiredthe breaking and remakirtgof electricalconnections then the checks - A. Earth Continuity,C. Polarityand D. Resistanceto Earth - must be repeated. PreliminaryElectlical System Checks accordingto Instructions Push Main Switch for BritishGas into posilion l. Multimeter. Replacefaulty Neon and refil Main Switch Cover. Replacefarlty P.C.B. with Main Switch. ReI. to note 1. 48 CheekOperaling ol HeatingSystem (Sheet3) Check Operationot DomesticHot Water System (Sheel 6) Check switch lor DomesticHot Water (She6t5) Note 1 : Detach the Jollowing parts oithe control box: - unscrew the cover of the terminal box - unscrew upper part ot control box (2 screws) and press it a little bit upwards - unscret/v knob of boiler thermostat - unscrew front panel ot control box with switch group - pull off multicontactplugs Aand B - remove printed circuit by loosening the two screws beside the switch group - install new orinted circuit 49 9.3. Sheet 3: Check Operation of Heating System (Do not use domestichot Water,switch for domestichot water remainsin PositionZl) ' ls voltage \ Push HeatingSwitch 240 V AC trom Can Pilot be Iit? Switch give into positionl. . light? / ls Overheal CufOfi Device of Overheat- Cut-Off-Device @on P.CB tat'f 50 ls voltage Flepeatthe tollowing 2ZIOVAC Does Main checks: trom teminal Burnerlight? A. Earth Continuity. C. Polarily. D. Besistanceto Earth accordingto Instructions for BritishGas Multimeter. Are external €*t Overheat Go to sheet 4 :,t-Otf Device. Thermostats eef. lo note 2. tested? contacts -:Eck Fleplacefaulty d Overheat Thermostat. :loff Device. a€i. to note 3. Ret.to note5. Check that Check external arid Multiplugs@ Thermostalsaccorclino ' : ile clean, tight to lnstructionstor ild mrrectly BritishGas :r:siti.cned. Ref. Multimeter. note 4. Note 2: For re.s€tting, press the black rubber butlon on right hand side of control box behind the terminal box. Note 3: For this purpose, open the control box as describ€d in Note 1. The overheat cut-off device isiitt(i on right hand side ofthe control box- Checkitthe flat plugs ofthe overheat cut-otl device are tight. Nole 4: For this purpose, open the control box as described in Note 1 Pull off the multicontact plugs A and B and check that not contact lugs are bent. It necessary, readiust contact iugS and reset multicontact plugs again. Note 5: To check, disconnecf contrclsystemlrom terminals 3 and 4, and replace with wire loopto run boiler in heating mode. 51 9.4 Sheet 4: Check Electronic and Hydraulic System / lsvoltage \ 5tol5VDCatDC Check that MultiplugA Check that wire is connectionsare clean, ls MultiplugA connectedto Terminal tight and correctly tested? l, ll or lll. positioned. ReL to note 10 Pull otf connection ls NTC probe of NTC probe. Replacefaulty P.C.B. tested? Ref. to note 7. with Main Switch. Ref. to note 1. z ' ls voltage ls Micro Check grey connections tol5VDCat Switchon on FFD Micro Switch Solenoid?Ref. to FFD tested? lor 24OV AC from Terminal5 to connections.Replace Micro Switch if faulty. Check black connections Replacefaulty on FFD Micro Switch NTC probe. clean, tight and correctly oositionedtor 5 to 15 V DC from brown connectionon DC solenoidto black FFD connections.Reolace Micro Switch if faulty Ret. Nole 6: The D.C.-voltage of 5-15 V is to note 8. controlled at the supply terminals of the solenoid vatue. Attention! Re{itconnection When the indicator tums.to the to NTC probe. left, the measuring lines must be reversed. On ignition ot the bumer there must be a D"C.-voltage ot 15 V. Hasfuse on The voltaqe decroases Electronic according io the flow P.C.B. temperature until the electronic (at approx. 5. V D.C.-voltage) tums oft the solenoid valve Replace0.25 Amp. (dead) and the burner fuse. extinguishes. Note 7: Thls test shows whether the NTc-sensor has an inner shorl Replacetaulty circuit (resistance down at zero). ElectronicP.C.B. For this purpose, pull the NTC- Ref. to note 9. sensor plug off when the appliance is cool (Jlow temperature less lhan 50'C). lf the electronic is satisfactory, the appliance must operate. 52 Repeatthe following cnecKS: A. EarthContinuity. Does DoesMaan C. Polarity. Pumprun? Burnerlight? D. Resistanceto Earth accordingto Instructtons for BritishGas Multimeter. Are Pump Difterentral Setting Valve Terminals tested? tested? 240 V AC lromtermrnal 5tol. ReplacefaultY DC Solenoid. connectlons on FFD tested? Move HeatingSwitch ON-OFF-ON.Diaphragm pin on Difterential Valve has to move OUT-lN-OUT.If not, '1 . Clean Venturi Checkpump accordrng 2. CheckDiaphragm to lnstructionstor at differentialvalve BritishGas Multimeters, and replace,jf necessary. Procedure9. Ref. to note 11 . not be connected to the Attention! Pull otf the NTC-plug for a short time only be- Note 1O: Attention: External llnes must lll (shortcircuit!) cause the normal temperalure control is terminalsl, ll and functionin that position.In this case the out of cable can be connected to terminal l, ll or I ll ' is only protectedby the overheatcut- The black appliance It must be checked whether the black cable is off device. ) .! connected tightlY enough 8: For this purpose, open the control box as described in Note the diaphragm pin cannot be Note 1. Unscrew the pilot gas tubes of the thermo- Note11: lf the movement of pressure ditferential switch must electric casing and check it the black cables oJ the checked optically. the the 3 screws Do not micro switch are tight. be removbd by unscrewing unscrew the two connection tubes! AfteMards installpilot gas tubes again Under perfect function the diaphragm pin cannot be Before re-assemblingthe controlbox. check the fine- pushed back by hand, when pump oprates.lf lhis is, wire tuse of the eleitronic. lf necessary. replace it' however, possible, the venturi tube' Pressure Attach plugs A and B again and re-assemble control difierential iwitch, connectionstubes or pump, must be box. checked. Special attention must be given to the tact that the venturi O-ring ist nol damaged. 9:- For this purpose, open control box as described in f.fotef . Pull'off the multicontactplugs A and B The electronic-printed circuit can be removed .by unscrewind the cross-recessed head screw on the left hand siddof the control box. Pull out the printed iircuit towards the front and pull off the multicontact plug as well as the white cable. Install the electronic-printed circuit in reverse order' RE t"- 9.5 Sheet5: GheckSwitch for DomesticHot Water (HeatingSwitch in position"O" do not usedomestic hot Water) -Does Pilot SetSwitch for Can Pilot be lit? lamp in Main Switchgive DomesticHot Water to positionI 1 light? - Go to sheet 2 Device(Ret. to note 2) and check connections n if no voltaqe240 V from lermin;l 5 to 4. Check Micro Switch M1 by drawing hot water. Micro Switch M1 has to be actuated(closed) bv Switch Lever.Observ6 piston rising!Adjust or Micro SwitchM 1 no voltage240 V AC from terminal4 to 5 Bel. to note 12 54 Repeatthe tollowing checks: i - - A. Earth Continuity ls voltage Does Main C. Polarity. i 240VAClrom Bumer light? D. Resistanceto Earth accordingto lnstructions lor BritishGas Multimeter. NO Go to sheet 4 ls Overheat Cut-O'tf Device Switch M1 on llow switch tested? check that MultiplugA connstions ile clean, tight and corectly oositioned. "summei'is onlycontrolled by.the micro switch M1 ol theflow switch' Note | 2: Thetunction operatethe microswitch Duringdomestic hot t"t"iiiii'JtioiiinJi6itlct iug must Ml (close). adiustmentis necessary' lfthe microswitch is notoperated by the contactlug' an - otf the warmwater tap (apglign-ce^9.t1!otoDeration switch For this Durpose,open sivitch)bv meansof a mainswitch). ]lghten tnJiiri oi tne'iwititr'roit(top ol flow LgftT#';lT'lJ$s'#"HlFr'IH!."*frg:::Jlli:"":HL"Iill )li,j"i not iouin tn" casingof the microswitch' Note 13: See tigure 99 for micro switch Ml' 55 9.6 Sheet 6: Check Operation of Domestic Hot Water System (Heatingswitch in position0 switchfor domestichot water in positionZll - Heating \ Set Heatinq "o-" Can Pilotbe lit? lampin Main Switchto l. Does Switchlo Switchgive . Main Burner and draw hot water 1 light?-z Go to sheet 1 Go to sheel 2 Go to sheet3 .l Note 14: For this purpose, open the control box as described in Note and remove front panel. Thus the micro swilch is accessible and the movement of the switch Dinof the water section can be observed. Ooen the warm water tap. With a water flow.quantity ol approx. 1 l/min. the switch pin must move and operate the micro switch via the switch lever which can be adiusted. lf the switch pin of the wdter section does not hove, the water section must be removed and checked (diaphragm). lf the micro switch does not operate despite the fact that the switch pin moves, the switch lever must be readiusted. For this, unscrewthe support ofthe micro switch and push itdownward until the switch lever contacts thetop oiwater section. Fix the suOport in this Dosition. 56 R€peatthe tollowing - \ lsvoltage Does checlG: 240 V AC from Main Burnet A. EarthContinurty. C. Polarity. D. Resistanceto Earth accordingto Instructions tor BritishGas NO Mullimeter. 4 lsWater Swkh off electricRy, Slection t€move Control Box tested? Cover. Ooen and close hot water iap. Diaphragm Din of waler seclion has to move up and down. Draw otf one l/min. and Pin has to be in upper positjon. lf not, clean Water Sedion according seruicing instructions. Ref. to note 14. Switch on eleeticity. - ' lsvoltage 240 V AC trom Close Control Box. Adiust Swilch Lever ls Micro by slac*ening screw Swildt in elongated hole. acluated? Bet. to Note 14. t ls voltaoe\ 240VAC?om Beplace Micro Switch. 57 U6 IUI- VCW-sine 18 TgW vcw20/1T3w t(vl! vcw2s/1T3w lValllantl L-- OVERHEAT CUT-OFFDEVICE HEATING DIFE PRESSSWITCH SWITCH (DOM.HOT WATER) 412 br FLOWSWITCH A1 to A12 = MultiplugA 81 to 811 = MultiplugB E1 to E12 = MultiplugElectronic Single Plug on Electronic T2toTs = Terminals bkl to bks= BlackWire with MarkingNumber 810 gv TIME FROST STAI CONTROL ANDTOR ROOMTHERMOSTAT NTC-RESISTOR Fig. 98 58 vEffi$iii#*M FLOWSWITCH NTC_RESISTOF OVERHEAT CUT-OFF \ DEVICE I z cc oF U J Fig.99 i o 59 Fig.100 12 11 E 3 9 Fig.103 9 o Fig.105 60 10 Short Part list Key Description PartNumber G.C. Number No. 1 diaphragm 01-0318 262329 2 washer 98-0151 262335 3 diaphragm 02-0220 262356 4 overheatcut-offdevice 10-1363 262494 5 flowthermometer 10-1002 263906 6 pressuregaugq 10-1008 262907 7 switchboard 13-0132 262489 I screw 07-0334 9 support 08-6165 263986 10 piezo-unit 09-1008 263987 11 knob 14-3935 262488 12 '13 screw 14-0012 '14 automaticairvent 06-1704 263935 expansionvessel 18-1001 263950 15 draughtdiverter vcw...20 07-3965 262418 vcw...25 07-3966 262419 16 sidepanel righthand VCW...20,VCW-sine 18 07-1143 262446 vcw...25 07-3730 262427 17 sidepanellefthand VCW...20,VCW-sine 18 07-1144 262425 vcw...25 07-3729 262426 18 frontpanel vcw...20,25 07-1043 262437 VCW-sine18 07-4161 .263973 19 centresection vcw...20,25 07-1044 262439 VCW-sine18 20-8619 263974 20 door vcw...20.25 07-1046 262433 VCW-sine18 07-4008 263976 21 support 15-4n5 262416 22 protec{ioncap 07-2306 262398 23 burnercomplete VCW...20NaturalGas 04-4563 262382 VCW...25NaturalGas o4-45U 262383 24 thermocouple 17-1125 262402 25 knobcomplete green 11-4208 262477 red 11-4209 262478 26 cover 07-2313 262223 27 ductbolt complete 094102 262216 28 hightension lead 08-4432 262215 61 11 TechnicalData Type VCW VCW VCW-sine18 2011T3W 2511T3W T3W Nominalheating capacrty 24 )64 (81e00) (e0800) (66500) (BTU/h) (86,4) (7O,2) (MJ/h) Nominalheating input 31 26 (basedon grossC.V.) (105800) (1212OO) (88700) (Bru/h) (11 1,6) t1t7 A\ (e3,6) (MJ/h) Pilotburnerjet size lorNG 34 34 40 marKrng ! Mainburnerjet size IorNG 14x7h30 16x7/1 30 12x1 125 numberx mark Burnersetting pressure 9,0(3,61) 9,0(3,61) 10,6(4,26) mbar (inWG) Minimumwaterllowlor 1000 1250 900 Vh "C heating system 20 rise (222\ (200) (lmp.Gal./h) Deliveredgas G20 G20 G20 GrossC.V.(s.t.p.) 39,9(1 070) s9,9(1 070) 39.9(1 o7o) MJ/m3(BTU/cu. ft) Gasconsumption (s.r.c.) 2,95(1 ,741 3,38(1 ,99) 2.47(1,45) m3/h(c.f.m.) Nominal capacity 24 26,6 19,5 for domesticwater (1365) (151 3) (11 09) (BTU/min) Nominalcapacity (water f low) 7,6 Aq 6,2 limin(45 K rise) 'F ofdomesticwater (1,67) (1,87) (1,36) (lmp.G./m. 81 rise Water capacity ol 0,26 0,30 o,26 I heatexchanger (0,057) (0,066) (0,057) (lmp.Gal.) Nominalsize 125 mm oftlue pipe (5) (in.) Max.nominal "c flowtemperature 90(1 s4) fF) Milimum total water- capacity of heating system(cold 1)) forsealedsystem 260(57,2\ l(lmp.Gal.) Maximum water pressure 1O(142J bar(P.S.l.) Minimumstatic head for open heatingsystem 0,15(2,13) bar(P.S.l.) Minimumwater pressure for domestic water supplyof 1 l/min. o,2(2.84) bar(P.S.l.) f, Pumppressure available for central heating system applianceas deliveredabout 0,25(8,4) bar (feet) UPS 18-60 spare head about 0,205(6,9) bar (feet) Weigth 59 (130) 60 (132) 68 (15ol kg (pound) Electric Voltage 240/50 VlHz connection Input 120 internalFuse 2 Amp (slow) externalFuse 3 Amp (slow) 1)For systemshaving a largerwater capacity an additionalexpansion vessel can be installedeasily. Subject to alteration. Headquariers Central Region Office Northern Region Otfice Vaillant Ltd. Vaillant Ltd. Vaillant Ltd. VaillantHouse Unit 5 VaillantBuilding Medway City Estate Providence lndustrial Estate Euroway Estate Trident Close Providence Street Wharfedale Road Rochester/Kent Lye, Stourbridge Bradford MEz 4 EZ West Midlands DY 9 8 HO West Yorkshire BD 4 6 SB Tel.0634-712868(Sales) Te|.0384€91816(Sales) ret.0274-688322 Te|.0634-712844(Service) Te|.0384{93368(Seruice) (Sales/Seruice) 0891b - Printedin Germany- lmprimden Allemagne