Service Manual

Continuous Flow Water Heater

Important.

Read these instructions carefully before attempting installation or use of this appliance. All work must be carried out by competent persons.

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June 2010—Issue 1

This manual is intended for use by Gas Safe

Regisetred Engineers

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CONTENTS

Glossary of terms and Symbols…………..………..…….…………………………..….5

1. Introduction …………………….………...……...………………….……………6

2. Specification ……………….…………..….…..………………….………………7

3. Water Flow Rates and Pressures …………..…..……………………………...… 9

4. Dimensions …………………………………...…...……………………………10

5. Remote Controls……………………………….………………...…………….....11

6. Cutaway Diagram……………………………….……………………………......14

7. Operational Flow Chart……………………….……………………………….….16

8. Main Components……………………………….…….…………………………..17

9. Wiring Diagram………………………………………..……………………….....19

10. Dip Switch Setting……………………………………..……………………...…..20

11. Error Codes……………………………………………………………………..….21

12. Diagnostic Points………………………...…..…………………………..….…..…22

13. Gas Pressure Setting…………………………..……...…………….……..……….23

14. Servicing………..……………………….….………………………….……….….25

15. Spares List………………………………………………………………………….28

16. Warranty….………………………………..………………………….………..….35

17. Contact ….…………………………………..……………………………………..36

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Glossary of Terms and Symbols

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Introduction

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Specification

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Specification

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Water Flow Rates and Pressures

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Dimensions

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Remote Controls

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TEMPERATURE CONTROLS - OPERATING

Using 2 or more Universal Temperature Controllers. Switching the system ON. The hot water system and all controllers can be switched ON and OFF from any controller by pressing the ON/OFF button as shown. When the system is turned ON the water temperature display will be lit. During normal operation the system is left ON. Do not push the ON/OFF button when water is running. Using hot water. Ensure the system is switched On by verifying the temperature display is lit. Ensure the local controller has priority by verifying the Transfer LED indicator is lit. If it is not then press the Transfer button once. This gives the local controller priority of temperature over the system. Select the desired temperature using the Hot water temp. buttons. The selected temperature will be displayed on all controller displays. This is the water temperature which will be supplied from the heater. Bathroom temperatures should be no more than 50°C. Open the hot water tap. The appliance will be activated and the In Use indicator will be lit.

Using 4 Universal Temperature Controllers. You will need to activate the fourth controller. STEP 1: On the Master controller press and hold the Transfer and ON/OFF buttons simultaneously (see Fig. 2) until a “beep” is heard (approx. 5 seconds). STEP 2: Check that the display on all Four controllers is lit and displaying a temperature when switched on. If any ONE of the controllers displays two dashes (see Fig. 1) in the display repeat STEP 1.

If the master controller is replaced, repeat STEP 1 above for the new controller.

NOTE

Fig. 1

Fig. 2

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Do not push the ON/OFF button on the Master controller after transferring priority of temperature selection to a Secondary controller as the system will shut down. Do Not Turn OFF the Master Controller

Temperature priority cannot be switched to another controller when the water is flowing through the water heater.

Depending on the weather conditions and the length of the pipe between the heater and the tap in use, there may be a variation between the temperature displayed at the controller and the temperature at the tap.

Do not clean the control with solvents or detergents. Use only a soft damp cloth.

TEMPERATURE CONTROLS - INFORMATION

If a temperature over 50°C has been selected on a controller and priority of temperature selection is transferred to another controller, then back again, the temperature on the controller will automatically drop to 50ºC. If the set point is 50°C or less it will not alter. This is a safety feature.

Controller 1 in use

Controller 2 cannot take

priority

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Kitchen Kitchen

Bathroom

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Cutaway Diagram

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Cutaway Diagram

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Operational Flow Chart

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Main Components

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Main Components

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Wiring Diagrams

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Dip Switch Settings

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Error Codes

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Diagnostic Points

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Gas Pressure Setting

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Gas Pressure Settings

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Servicing Burner

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Servicing

ANNUAL SERVICE See Page 25

Isolate gas supply and electric supply

Remove Front Panel by means of 4 corner screws

Remove all screws around outer edge of manifold (11) and remove

Inspect and clean injectors on inside of manifold (B). If heavily contami-

nated remove front cover plate (A) and clean from inside out

DO NOT RE-DRILL or ENLARGE ORIFICE

Remove Ignition lead and Ionisation lead

UNLESS GASKET (F)* IS AVAILABLE DO NOT REMOVE SCREWS (E)

Remove remaining screws holding Combustion Chamber Front Cover (10)

and Remove Cover Plate

Inspect and clean Ignition (C) and Ionisation Electrodes (D), Inspect for

cracks.

Remove 2 screws (12) on ledge of main burner box and remove complete

burner

Clean burners (G) with air brush and paint brush

Should any burner require individual attention undo screws (H) and remove

retaining bracket (I)

Inspect Combustion Chamber and base of Heat Exchanger. Check for signs

of damage / leaking

Disconnect fan wiring (J)

Remove 3 x Fan retaining screws (13) and remove fan from unit

Inspect fan Impellor and clean as require

Re Build in Reverse Order

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Servicing

Isolate water connections below heater

Remove Filter (14) Inspect and clean as required

Replace and re-instate water supply

Remove gas valve (15) test nipple (K) and connect manometer

Re instate Gas supply & Electric Supply

Open water outlet and get maximum water flow possible

Check burner pressure as per page 23

Once burner pressures have been checked and correct turn off water outlets

Isolate Gas supply and remove manometer & Reseal Test Nipple

Reinstate gas supply

Open water outlets and fire heater whilst running check all test nipples for gas

leaks.

LOW GAS 11e 14e 17e 20e

NG G20 1.68 1.68 1.68 1.72

LPG G31 1.55 1.55 1.55 1.78

(pressures in mbar)

MAX GAS 11e 14e 17e 20e

NG G20 3.95 6.33 9.26 8.68

LPG G31 3.91 6.09 8.62 8.27

(pressures in mbar)

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Spares

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Spares

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Spares

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Spares

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Spares

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Spares

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Spares

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U K Warranty

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U K Contact

Ver 1 19/10/21 RUK Tech Dept Ian Jenkins