S-WG 80 to S-WG 180 - Installation Manual V.1.09.08
Contents
1. Strebel WG Installation amp Service Manual 21 210806 doc DOC ICO dl Modustat Termostat Print all Strebel WG Installation amp Service Manual 22 210806 doc Control Panel Features ds UN Double pole On Off Switch O No Mains Power to the PCB Off Position Mains Power activated Unit is On Setting Turning the dial labelled SETTING enables the Hot Water Temperature of the tank to be adjusted and set By turning this dial the set temperature will be displayed When an outside sensor is connected the Hot Water Temperature set by the he2. TELFEETETEEETEDELETFTETEEETETETETETETETELECETETETETETETETET Parallel Flue Extension Piece Pitched Roof Flashing Parallel Flue Gas Roof Terminal Parallel Air inlet Roof Terminal Parallel 90 Bend Parallel Flue Gas Wall Terminal Strebel WG Installation amp Service Manual 15 Parallel Air Inlet Wall Terminal Weathering Cowl Ventilation grill Parallel Flue Connection with condense drain point 210806 doc Maximum Flue Lengths for co axial Flue Configuration Flues must be installed to current regulations 8 2 3 eee ee ee Diameter G H 80 125 80 125 Max Length G 45m 22m Max Length H 44m 21m Material Plastic or Stainless steel Strebel WG Installation amp Service Manual 16 210806 doc 8 3 Flue Capability The WG boiler has an excess pressure combustion system using a concentric flue arrangement of 80 mm within a 125 mm air tube over considerable distances All the boilers can be transferred to parallel tubes 8 4 The air inlet and flue gas outlet system The available pressure for the inlet and outlet system is 200 Pa without the output decreasing The graph to the left shows the reduction of kW output a
3. dig 14 Insp ctionrand Mainten nce ismimni sennoma ne iea a AEO E A EE EAE ENAA Eara NTAN EErEE EN EAEN 30 15 BE AE oo E E 16 Long Term Shutdown eese 17 Lock out User Complaint 18 Troubleshooting 19 Causes of faults 20 Troubleshooting Table 21 DiuuegGc EET 22 Maintenance cies E Strebel WG Installation amp Service Manual 2 210806 doc 1 SAFETY GUIDELINES 1 1 General guidelines Read all these instructions before commencing installation This appliance is free from any asbestos material It is the law that all gas appliances and fittings are installed by a competent person such as a CORGI registrant installer and in accordance with the Gas Safety Installation and Use Regulations the relevant British standards for installation codes of practice or rules on force and in accordance with the Manufacturers instructions The installation shall also be carried out in accordance with the following regulations codes and standards 1 2 British Standards and codes of practice e The Building Regulations issued by the Department of the Environment e The Building Standards Scotland Consolidation Regulations issued by the Scottish Development Department e The Local Building Regulations and Local water
4. Cause No Remedial Action 1 Check cable or replace the cable check that the cable is connected to the correct connector strip 2 3 Replace sensor or find cable fault 4 Try and loosen the pump spindle or replace the pump drive 5 Check water and detect leak 6 Too much water pressure drain 7 Place the plug with the cables on the fan side 8 Clean the fan blades 9 Replace the fan 10 Open gas valve 11 Check line and gas meter make a resistance calculation as required 12 Change gas lines 13 14 Check fuse F4 check all 230 V connections pump PCB 15 16 See paragraph 6 4 17 Check the cabling using the wiring diagram check the connection to the gas valve be aware of moisture 18 Check cable for short circuit overheating nearby or jammed between steel plate check spark plug cap for cracks replace cap 19 Replace the burner control 20 Moister trapped check the cable sockets which should fit tightly around the plug pins check the position of the cable socket possibly adjust before the plug slides in 21 Check that the plug s are fitting tightly 22 Open the drain line left hand side of the boiler by unscrewing the cap Keep a jug on hand to catch the amount of water drained Poke through the line using a pen moving left upward and right upward Take the burner unit from the boiler as required and pour some water in the heat exchanger to rinse out the siphon 23 Bleed the unit not only the boiler itself but
5. Depth Q 485 485 485 676 676 Please note More specific dimensions relating to the water heater amp cylinder are available on separate data sheets Strebel WG Installation amp Service Manual 7 210806 doc Diam 950 Circul 3 4 To boiler 2 From boiler 2 a ylinder Connections Dimensions Cylinder Size Litres 150 230 320 450 750 Connections to the Water Heater Male 1 1 2 1 1 2 2 2 2 Cold inlet Hot outlet Male 1 1 2 1 1 2 2 2 2 T amp P Valve Tapping Female Circulation connection Male 3 4 3 4 3 4 3 4 3 4 Thermometer connection Female 1 2 1 2 1 2 1 2 1 2 Height mm 1390 1430 1750 1645 1850 Diameter mm 510 605 605 735 950 8 210806 doc Strebel WG Installation amp Service Manual Hot Water Outlet T amp P Valve CYLINDER Non Return Valve Boiler Return Operation of the Strebel boiler The domestic hot water boilers from the STREBEL series are Direct Fired Hot Water boilers with maximum high efficiency Such performance can be reached by among other things using a special heat exchanger made of stainless steel The heat exchanger allows flue gases to cool down below condensation point condensing the flue gases and releasing extra heat This has an immediate positive impact on the efficiency exceeding 100 6 3 Description of the Hot Water System The water heater works according to the loading principle the moun
6. display console namely to adjust settings or to get information Symbol Meaning OFF 0 No Demand On Demand the required boiler temperature is shown on the Display Service Button e In order to set the gas valve for the maximum output as well as for the minimum output the appliance has to be put into the SERVICE mode Press a ballpoint pen or similar into the small hole beneath the plastic cap at the right side of the control fascia see page e By turning the CH knob the speed of the fan can be set between the maximum and minimum speed The display will show the speed of the fan e g 25 means 2500 rev min After 10 min the boiler switches back to the automatic program If the setting of the gas valve is not complete press the switch again e The temperature of all the connected sensors can be shown without the help of a laptop on the display Press the RESET button the first temperature is now shown blinking together with the code of the sensor blinking To see the temperature of the next sensor press again the RESET button Preparation for light up Fill the calorifier and the Boiler system using the appropriate filling method The correct fill pressure is gt 1 bar max 6 bar Pay attention to the following aspects in order to have a clean system e Thoroughly power flush out the hot water system removing all traces of flux and debris e Check the circuit for leaks and repair to prevent oxy
7. of sufficient size with a opening Temperature of 100 C and a pressure of 10 bar is installed on the top of the tank a adequate tube including a tundish has to be installed by the installer Strebel WG Installation amp Service Manual 4 210806 doc INSTALLATION of the STREBEL WG 3 1 Unpacking Unpack and check all items delivered immediately upon delivery and report any shortages or damage Re pack all items for protection until installation is required The Strebel WG comes with the following documents and accessories 1x Installation amp Servicing Instructions for the installer 2x spare fuses and 3x spare nuts for mounting the burner plate attached to the front of the gas valve 1x dirt catcher siphon with nut and gasket On delivery immediately unpack and check that the Strebel WG is complete and without any defects Report any damage immediately to Strebel Ltd Re pack the goods for save keeping until installed Important Strebel WG boilers are set for natural gas group G20 3 2 Select the mounting position in the building Installation must be carried out in accordance with Gas safety Regulations 1998 Building Regulations the Supply Regulations 1999 and the requirements of the local Gas Authority Water and Fire Authorities and the current B S and Codes of Practice listed in chapter 1 1 A gas isolation valve should be installed in the room where the Strebel WG unit is to be installed The water heater shou
8. plastic cap at the right side of the display By adjusting the SETTING Dial the speed of the fan can be set between the maximum and minimum Fan speed The display will show the speed of the fan e g 25 means 2500 r min After 10 minutes the boiler switches back to the automatic program If this occurs when the setting the gas valve press the SERVICE Button another time to continue making the required adjustments e Without the help of a laptop the temperature of all the connected sensors can be shown on the display By pressing the RESET button the first temperature is shown blinking together with the code of the sensor blinking o To see the temperature of the next sensor press the RESET button again FL temperature Flow temperature rE temperature Return temperature dH temperature Hot water temperature cA temperature Temperature of the external Sensor The Strebel WG Range has an automatic de aerator on the top of the boiler This must be opened when the boiler is put into operation N B Check that the screw cap has been turned loose at least one twist Putting the WG out of operation Put the On OFF switch in position OFF Drain the hot water boiler and the system in the event that the boiler is put out of operation during sub zero temperatures Open the filling and drain valve of the hot water system and the boiler drain valve on the right hand side of the boiler Strebel WG Installation amp Service Manual 26
9. 09 5 109 5 Nominal output at 80 60 C kw 70 8 87 6 106 132 160 Nominal output at 50 30 C kw 16 78 19 97 24 116 20 144 27 175 NO x emission mg kWh 15 15 15 15 15 CO emission mg kWh 20 20 20 20 20 Technical details CO2 flue gas 8 8 Dew point combustion gas eC z 53 Temp Flue gas by ambient temp 20 C C 80 Available pressure for the Flue system Pa 200 PH value condensate pH 4to 5 5 Available DHW pump pressure for the installation dui 25 25 3 0 15 1 0 Max outlet temp c 80 Pressure DHW system min max bar 1 0 10 210806 doc S WG Water Heater Technical Data Table S WG Water Heater Dimensional Data Table 150 Litre 230Litre 320Litre 450Litre 750 Litre Dimension Cylinder Diameter A 510 605 605 735 950 Cylinder Height B 1390 1430 175 1645 1850 Thermometer Connection C 1065 1125 1410 1230 1400 Cold Mains Feed D 250 250 250 300 345 Hot Water Outlet E See separate individual cylinder data sheet for specific dimensions T amp P Valve Connection F See separate individual cylinder data sheet for specific dimensions Return to Water Heater G 250 250 250 300 345 Flow from Water Heater H 55 55 60 60 60 Frame Height J 1570 Frame Width K 550 Frame Depth L 530 Frame Leg Height M 760 Water Heater S WG 80 S WG 100 S WG 120 S WG150 S WG180 Height N 835 835 835 889 889 Width P 458
10. 210806 doc Putting into operation for the first time Once the system has been tested and everything is in order according to this manual connect the mains power and turn the boiler on using the ON OFF switch With the boiler turned on the display will be showing the set water temperature The burner control will repeatedly give an electronic spark for ignition until a flame appears If no flame appears after several attempts check that the gas valve has been set correctly Strebel WG Installation amp Service Manual 27 210806 doc Adjusting and setting the Output When setting a gas control valve set via measuring the CO percentage Setting the combustion The CO should be set to 8 8 0 3 measured without boiler front door in place e Press the SERVICE Button and set the SETTING Dial to the maximum fan speed The Fan speed is shown on the display e g 25 2500 r min If the measuring process takes more than 10 minutes the boiler will return to the automatic mode If required press the Service button another time When finished wait for the full 10 minutes or press the SERVICE Button again Turn the SETTING Dial until the maximum RPM setting has been reached T e In order to set or adjust the max
11. Codes of Practice to other premises have been published HS G70 and CIBSE TM13 The design and operation of water systems with reference to avoid of factors that favour colonisation by Legionella including stagnation lukewarm conditions 20 C to 45 C and the accumulation of debris scale and corrosion in the base of tanks and calorifiers Strebel WG Installation amp Service Manual 3 210806 doc 2 1 Special Precautions Take Care The quality of the potable water should not exceed a hardness of 25 D Take Care Do not use Aluminium Flue gas tubes Condense runs towards the boiler outlet use extra condense traps and siphons Use stainless steel or plastic PP flues Take Care The boiler is used in combination with a hot water tank without any other heat exchanger the tank should be equipped with a T amp P relief valve Take Care The connection for a Remote DHW Stat is based on a OpenTherm Bus system special Control from Strebel or an On Off timer Take Care After installation the built in Air Vent must be opened Local regulations apply and must be adhered to along with the following Only an approved installer is allowed to install an unvented system o A Mains Unvented Rit for sealed Systems is required A expansion vessel is needed for this installation The maximum working pressure test pressure of the system should not exceed 10 bar o A Temperature and Pressure safety valve T amp P valve
12. E STREBEL HEATING TECHNOLOGY H9 o Installation amp Service Instructions CE 0063 2006 080606 500 Strebel WG Installation amp Service Manual 210806 doc STREBEL Lid is not liable for any damage caused by inaccurately following these instructions Only STREBEL Ltd parts may be used when carrying out any repair or service works 1 1 General guidelines 1 3 Health and safety regulations 1993 1 4 Legionella 2 1 Special Precaution EE 4 CNN PACKING 5 3 2 Mounting Position 4l Technical Data oO HO Ute ue alia ee Fete Cr a iii 6 5 Front ViCW si 6 Combination Supplied 6 2 Operation 6 3___Description of the Hot water System 7 Modulation csi ssci 9 7 4 Water Quality __ 7s2___ TG PVAWC R 10_ 7 3 Condensed Water dralh 22 eene alii aa AR denari giare aerea 11 7 4___Water connections 7 5 On off PUMP ARPA RE RAR E BO EE EEA i gris 12 7 6 Cooling of the Boiler 7 7 Frost protection 8 ay cn H PBREBRRUPEEEREE 13 8 1___ General 84 1 Maximum Fluelensths parallel rette ertet ttt et tee o ER rel re re r
13. In this case the total resistance of the flue components does not exceed 200 Pa This means that the output of the unit will not be affected by the flue resistance Strebel WG Installation amp Service Manual 18 210806 doc Remote Fault Through the use of a external power e g 230 VAC this Volt Free contact closes in Lock Out Control LO condition E g a lamp or a buzzer can be connected Relays are build in the boiler control Parameter No change in Parameter required when connected Remote Through the use of a external power e g 230 VAC this Volt Free contact closes on Heat Demand signal for Heat E g a lamp or a buzzer can be connected Relays are build in demand O Xm e Parameter No change in Parameter required when connected The pump s are factory connected Pump is switched off when there is no heat demand after post running time Permanent Supply The permanent supply is connected to these terminals of which 19 is PE Ground The display has an ON OFF button to switch the boiler on or off Isolate at power supply before attempting any work The electrical connections to the WG are made via discreet plugs and sockets which are located within the boiler case on top of the control panel Connections must only be made using appropriate diameter multi strand flex cables and cable entry must only be via t
14. O is roughly between 9 5 and 10 e High Fire CO must be set to less than 100ppm CO e Low Fire CO must be set to less than 10ppm Strebel WG Installation amp Service Manual 29 210806 doc 14 INSPECTION AND MAINTENANCE General The boiler requires inspection at least once every 12 months Li rule of thumb inspection maintenance is to be carried out also when the boiler generates a number of similar error codes Major Service An inspection should cover at least the following matters a Ask the user about any problems with the CH boiler and or any comments b Check the system water pressure Minimum 1 bar Remove the casing of the boiler and check all lines and connections for traces of water and water leakage d Inspect the top of the casing and or the top of the boiler for water leakage or traces of water from the air supply pipe or the de aerator e Open the condense siphon and remove any dirt f If a laptop computer is available connect this computer and check the service page for error messages starts and failed successful starting attempts g Fire the boiler on maximum output and measure the output and the CO2 percentage CO on LPG h Fire the boiler on minimum output and measure the output and the CO percentage CO on LPG i Note the noise of the CH pump and the fan Dismantle the burner unit remove the 6 x M6 nuts and the ignition cable and move the burner unit forward Re move the plug
15. and left hand side of the boiler e When restarting the system and restarting the boiler treat the system as a new system and its com pliance to this manual STREBEL Lid is not liable for any damage caused by inaccurately following these instructions Only STREBEL Ltd parts may be used when carrying out any repair or service works Strebel WG Installation amp Service Manual 32 210806 doc 17 LOCK OUT User Complaint As the burner control goes into Lock Out the display will show a code see also 8 3 page 27 which corresponds with the cause of the error The table below shows the errors Only by pressing the RESET button can the boiler can be reactivated a Code on Possible cause of the Lock Out Meaning Display See fault numbers Page 34 to 37 Short Circuit in Ionisation Circuit FO 18 35 61 Limit Temperature F2 4 5 21 23 24 29 30 42 46 Wrong Fan speed F4 7 8 9 13 19 39 40 41 No Flame after 5 Ignition attempts F5 10 11 16 18 22 25 35 Flame lost 4 times during running F6 10 12 16 22 25 26 32 44 Flow sensor shorted or interrupted EO 4 5 23 29 46 El 3 4 21 24 25 38 43 55 Return Sensor short interrupted E2 4 5 23 29 46 E4 3 4 21 24 25 38 43 55 E5 1 2 3 4 21 24 30 43 46 51 55 63 New Parameters programmed correct PP Press Re Set Button Parameters incorrectly programmed PE Revise programme Burner Control has malfunction nc Switch power off then on No communication in cascade mode nc Chec
16. ating curve will be displayed This set Hot Water Temperature can be shifted within 10 C and 10 C using the SETTING dial Triple Digit Display Always shows the set Hot Water Temperature except when the unit is in No Demand Status or Lockout Fault Status Green LED Indicator Burner Firing LED When the burner is On and ionisation is detected the LED is illuminated When there is no heat demand or no ionisation the LED will not be illuminated RESET Button When a code is flashing on the Triple Digit Display there is a lockout situation By pressing the RESET button the unit will begin ignition sequence again Please make a note of the code on the display in order to establish the reason for lockout SERVICE Behind the plastic cap is a plug for interfacing with a Laptop Computer via an interface cable Connection to this in conjunction with the appropriate software facilities will enable the operational parameters of the unit to be altered in the boiler control SERVICE Button Below the SERVICE plug connection is a small button within a hole recess which can be pushed with a ballpoint pen By pushing this button the unit will fire and the speed of the fan can be set by turning the SETTING dial The unit can be set back to automatic operation by pressing this button again Strebel WG Installation amp Service Manual 23 210806 doc Display console buttons There are a couple of uses of the buttons and knobs on the
17. by laws the gas services area and the Local Authority recommendations e Wiring to the appliance must be in accordance with the IEE BS 7671 Wiring Regulations the Health and Safety Document No 635 The Electricity at Work Regulations 1989 and any local regulations that apply e Relevant British standards insofar as the relevant areas that are not covered by these instructions e CP 342 Part 2 1994 Code of practice for centralised hot water supply buildings other than individual dwellings e British Gas Publications IM 2 purging procedures IM 5 soundness testing IM 11 IM 16 Installation of gas pipe work and boosters e HSE guidance note PM 5 automatically controlled steam and hot water boilers e CIBSE IHVE Guide ports A B and C e IGE UP 10 IGE UP 2 and IGE UP 7 e IGE UP 2 Gas installation pipe work and compressors or industrial and commercial premises e LPGA Code of practice 7 Storage of full and empty LPG cylinders and cartridges Highly Flammable Liquids and liquid Petroleum gases Regulations 1972 e BS 5440 Parts 1 and 2 Flues and Ventilation Part 1 Specifications for installation of flues Part 2 Specification for installation of ventilation for gas appliances e BS5546 Installation of gas hot water supplies for domestic purposes e BS 6644 Installation of gas fired water boilers of rated inputs between 60 kW and 2 mW e BS6798 Specifications for installation of gas fired hot water boilers of rated input n
18. e e eodera pea o on E D isa 14 8 2 Flue terminal positions _ 82 I Air MaE Quiet CR 8 2 2 Parallel Air in and Outlet 8 2 3 Co axial flue maximum lengths s 8 3 FIue Capabilityi sanata oce trea E RE Se REFER SE SE e YU t STA Qo RA Cowes ii lite perme sem REFS cese c PERPE ALAN ein IEEE RUE 8 4 The air inlet and flue gas outlet system 8 5 The impact of the outlet to theload 8 6 WGresistancetable __ 8 6 1 Example Calculation 5 nke erro ee ea ea nono aoa SR ANAKAN FERE EERRER TT 18 9 EOCICQUE AU TD SERERE ESTEE TID TRE TUE HEEL DAN 19 10 Electrical 10 1 Connector strip 10 2 Phase sensitivity T 10 2 1 SOMSOMS IT 10 3 Fuses 10 4 Electrical circuit diagram 5 eiae eo eee ee ee oon naro noun pro AAKA ao Eo nu ER nA yy RR YER ER RRRRRIR iii ieri 21 10 5 PCB with plug TulmDGrs scii sc inane eut ib dd nae ima In Cot bPe e eo aa Eon aset anb tea TR RR ada S Reg eri ia 22 11 Control PAN 23 11 1 Settings PENCIL ERES 11 3 Display codes 12 Starting the boiler 12 1 Putting into operation the first time 13 Adjusting and setting the output 13 1 Setting the Maximum Output 13 2 Setting the MINIMUM OUEDUt iius risa sectae ote go tea be lidia necesse Ecco iii EAT ARAN JC Sc Ner Noo pe e
19. ered by the warranty of the Strebel WG Unit 7 4 Water connection The cold water connection 1 72 ID is to be found at the bottom rear of the tank while the hot water connection 1 72 ID is situated at the top of the tank e A circulation connection 3 4 OD is placed at the right hand side of the tank app 30 cm from the floor A connection is available for a thermometer 1 2 ID atthe topside remove plug of the cylinder e To prevent heat losses of the system there is a built in non return valve in the return connection to the boiler To prevent contamination of the Strebel WG heat exchanger fully rinsing the system with clean running water prior to first use is required Strebel WG Installation amp Service Manual 11 210806 doc 7 5 On off pump The on off pump s has a speed regulator adjusted to the highest setting Do not change this setting e The boiler control is equipped with a safety device for controlling the volume of the pump when the volume measured does not match with the safety setting the display will show a blocking of the boiler after 4 blockings there will be displayed a Lock Out signal After pressing the Reset button the boiler starts to work again but now at 50 of its output please call your installer in this case e The Strebel WG control has a built in pump switch with a standard 1 minute overrun The pump will work at top speed when heat is required Whe
20. ervice Manual 34 210806 doc 19 Causes of Faults Table Continued Cause No Cause List 46 Setting of the RPM switch of the pump is too low 47 Sensors changed around return sensor S2 and hot water sensor S5 48 Fuse F1 Automatic re set 49 Fuse F2 Automatic re set 50 Line voltage 230 VAC 51 Parameter s in the installer program entered incorrectly 52 incorrect connector strip port 53 Pulse width program in the installer menu incorrectly programmed or steps are too long 54 Clock program 55 Flow and return on the boiler have been changed around 56 Cable or plug connected incorrectly 57 Priority sensor S3 not placed correctly or defect 60 Cable harness connectors incorrectly mounted on the PCB 61 Gas safety valve defect 62 After programming using the computer confirms the new settings 63 Incorrect parameters or values outside the range of the program have been entered 64 The burner control is frequently checking the supply voltage 65 Mechanical defect in the Reset key when H is blinking when the H is not blinking the burner control is defective 66 Gas valve is not correctly adjusted at maximum input Strebel WG Installation amp Service Manual 35 210806 doc 20 Troubleshooting Table Please cross reference the Cause No from previous Pages with the table below to establish the remedial action required
21. fan is too high TS Wait until the speed is OK Speed of the fan is too low Water flow through boiler too low Wait till gradient is ok High limit thermostat is active Wait for cooling down Power limitation 50 after too many gradient blockings Error Codes Lock Out Status Call your installer As the burner control goes into Lock Out the display will show a blinking code which corresponds with the cause of the error the table below shows the errors The unit can only be reactivated by pressing the RESET Button Flame lost 4 times during Running Parameterprogremmes TO Fe Strebel WG Installation amp Service Manual 25 210806 doc Starting the boiler General Measure the connection pressure in the gas pipe at the pressure nipple 3 of the gas valve The minimum connection pressure needed for the boiler to work properly under the correct load must be higher than 10mbar However the gas pressure must comply with current local regulations Installer program Using the control facilities on the Control Panel it is possible to set parameters and obtain information 0 on the display means No heat Demand On Heat Demand the required Set water temperature is shown on the display SERVICE button In order to set the gas valve for the maximum output as well as for the minimum output the appliance has to be put into the SERVICE mode Press the SERVICE Button with a ballpoint pen beneath the
22. gen from entering the system The boiler has an automatic air vent not fitted to the SCB 60 at the top of the boiler this must be opened vvhen the boiler is put into operation Check that the A V screw cap is open by at least one twist Manually vent the SCB60 using a vent key Check all system air vents are open Shortly after putting the boiler into operation check the water pressure Cure any leaks on the and DHW system Strebel WG Installation amp Service Manual 24 210806 doc Display codes On the display when no code is shown e g A3 appears two possible indications Two digits on the display This indicates the Set Value of the tank temperature When the green led is not illuminated there is no heat demand e When the green led is illuminated there is heat demand and the unit is active Burner firing A blinking dot at the bottom right of the display means The Unit is incorrectly set for a cascade function Display codes without illumination of the green LED Burner Firing When a code is displayed the green LED is not illuminated it means that there is a heat demand but the boiler is temporarily out of order This is commonly due to the temperature of the unit being higher than the set temperature After cooling down the appliance will automatically start to function again Display Codes without Lockout Lamp Lit Outlet temperature too high Wait until temperature decreases Speed of the
23. gged 8 Fan has been damaged or dirty 9 Fan is defective 10 Gas valve not open 11 Gas pressure is too low 12 Gas pipe diameter is too small 13 Fuse F3 defect 14 Fuse F4 defect 15 Fuse F5 defect 16 Gas valve setting for lowest RPM incorrect 17 Gas valve is not or incorrectly connected to the power supply 18 Ignition cable incorrectly connected 19 Transformer defect 20 Connecting plug to gas valve connected incorrectly or moist inside 21 Power plug of the pump connected incorrectly 22 Siphon blocked 23 Opening and closing manual de aerator after bleeding 24 25 Too much resistance in the flue system or flue system is restricted or blocked 26 Flue system having a leak to the inlet system re circulation of flue gas only in case of concentric flue connection 27 28 29 Heat exchanger blocked insufficient circulation Contact Strebel 30 High limit thermostat defect insufficient circulation 31 Maximum load is too high 34 Burner control defect 35 Ignition electrode defect porcelain cracked incorrect distance to burner control 36 Moist or wet on the gas valve cables 37 Moist or wet on the PCB of the burner control 38 Moist or wet in the pump wiring 39 Moist or wet in the fan and or the fan connection 40 Fan plug connected incorrectly 41 Plug connected incorrectly 42 Damaged connecting cable 43 Sensor defect 44 Flue gas circulation from behind the heat exchanger 45 DHW leakage Strebel WG Installation amp S
24. he rubber gland cable points located at the bottom rear side of the appliance the low voltage cables at the left side and the 230 V cables at the right side of the boiler Strebel WG Installation amp Service Manual 19 210806 doc Phase sensitivity The Strebel WG Water Heaters are not phase sensitive Fuses On the PCB board there are 4 fuses of which only 1 can be replaced F1 Z The following temperature sensors have been fitted in the Strebel WG Units Sensors S1 The outlet water sensor on the front left of the heat exchanger 10Kohm 25 C S2 The inlet water sensor on the back left of the heat exchanger 10Kohm 25 C The sensors used in the Strebel WG Units are NTC type Negative Temperature Control and have the values shown below Temperature Resistance of Sensor C 1 amp 2 Ohm Strebel WG Installation amp Service Manual 20 210806 doc High limit thermostat pen indicat
25. ial Estate Frimley Road Camberley Surrey GU16 7PB Strebel WG Installation amp Service Manual Tel 01276 685 422 Fax 01276 685 405 Email info strebel co uk Website www strebel co uk We are pleased to inform you that additional information and literature is also available on our website 40 210806 doc
26. ilers E ALSO a x d Sz Es S x Xj XX XXX XX x CX X XXX L N 7 LE mil Le 7 d we t U ES T ze U v u i NN NON NNNNNNNN SORA ROIS BORA RAR RAIA SARA Pos 1 Coaxial Flue Extension Piece Pos 2 Flat Roof Flashing Pos 3 Coaxial Roof Terminal Pos 4 Pitched Roof Flashing Pos 5 Coaxial 90 Bend Pos 6 Coaxial Wall Terminal Pos 7 Coaxial Flue Connection with condense drain point Maximum Flue Lengths for Coaxial Flue Configuration Flues must be installed to current regulations Oo S ct mt PZ Diameter A B C 80 125 80 125 O di Material Plastic or Stainless steel with Condense Drain Connection Strebel WG Installation amp Service Manual 13 210806 doc Maximum Flue Lengths for Parallel Flue Configuration Flues must be installed to current regulations EET I ee ese Diameter D E F 80 80 80 80 Max Length D 60m 25m no air inlet Material Plastic Stainless steel with a Condense waste tube Strebel WG Installation amp Service Manual 14 210806 doc 8 2 2 Parallel Flue Configuration Separate Air Supply and Exhaust Pitched Roof amp Horizontal Termination
27. imum load use screw 2 for making the adjustment to the maximum setting Turn the screw clockwise to decrease or anti clockwise to increase the CO percentage COz measuring method Adjust the CO for the maximum output according following table Wobbe bw Mu m ees 41 52 76 64 Calorific Value net MJ m 34 00 88 00 CO max output 8 8 0 3 9 8 0 3 CO min output 8 5 0 3 9 5 0 3 measured without boiler door Strebel WG Installation amp Service Manual 28 210806 doc Setting the minimum output Set the minimum load once the maximum load has been set In service mode turn the CH knob until the minimum RPM setting has been reached 20 on the display In order to set or adjust the minimum load twist the screw 1 for the minimum setting Turn the screw clockwise to increase or anti clockwise to decrease the CO2 percentage see table 4a page 30 For S CB150 and S CB180 Boilers you are only allowed to set the gas valve on the right hand side DO NOT ADJUST THE LEFT HAND SI DE GAS VALVE For Gas Valve Adjustment see illustration on page 29 Figure 4 8 6 6 Gas conversion Converting from Natural gas to LPG Boilers with a single gas valve WG 60 up to 120 kW Boilers with a two gas valves WG 150 up to 180 kW NOTE e Set LPG by CO emission Setting LPG CO is not important because it is influenced by the quality of the LPG which differs quite a lot Mostly the measured C
28. k cables to all boilers and Bus address numbers Burner defect Hi Press reset button There are several faults or complaints that the boiler display is unable to convey Some of these faults or complaints are Complaint Cause of the fault see page 34 to 37 a The water is not warming up but the boiler is working 45 53 54 b Noisy ignition 16 35 c Burner of the boiler is continuously on but the water is not warming up 45 d boiler is not firing 1 42 52 e Burner of the boiler is continuously on wateris getting too hot 2 f Boiler is very noisy banging during operation 29 46 66 g Tops of radiators are insufficiently hot 55 h ON DHW the water is cold 24 56 i Temperature of the DHW is far too hot 51 57 j ON DHW the water remains below 60 C 51 58 k ON DHW the boiler is very noisy 23 59 l Fault after replacement of the burner control 60 Strebel WG Installation amp Service Manual 33 210806 doc 18 TROUBLESHOOTING Cause of the fault The faults listed on page 33 may have the following causes Cause No Cause List 1 incorrectly connected 2 short circuit in cable 3 Sensor causing short circuit in cable or internally 4 Pump not running has seized 5 Water pressure too low on external pressure gauge 6 Water pressure too high on external pressure gauge 7 Fan not connected unplu
29. ld not be installed in a location that contains a bed shower or bath Either side of the boiler must leave at least 20 mm empty space to walls or wall units e The water heater must be located in a area where leakage from the tank and or water pipes and connections safety valves and drains will not result in damage to the surrounding area When such a location is not possible suitable precautions must be taken Access must be provided to the front of the water heater approx 50 cm There must be sufficient space to the side of the unit for installing the pipework e There is no requirement for space either side of the unit for maintenance and service This also applies to space at the rear of the unit the appliance can be placed against a vvall The installation area must have the follovving provisions e 1 Wall socket with earth connection Connection to the sewer system for draining the unit and removal of condensation Other matters to consider when deciding on the location of the Strebel WG Unit The flue will be required to be terminated outside via a suitable wall or roof terminal e The installation area must be dry and frost free The WG Range incorporates a built in fan This fan does produce noise depending on the demand on the unit Customers are advised to locate the unit in an area where noise emission does not caused any disturbance In this respect Strebel Ltd advises mounting the unit on a solid co
30. ll eventually reach the siphon Adjust the drain line up if possible allowing the water to flow to the drain of the boiler d Act upon the findings from the service screen using the service program or a laptop computer if used and change any parts that may be the cause of these faults e Adjust the gas setting at the gas safety valve as necessary under minimum output f If the pump has become noisy certainly more applicable when the pump has been working for more than five years it is recommended to replace the pump motor as a precaution g Never clean the burner itself it is not required If dirt has built up on the inside of the heat ex changer and or scale has formed on the inside of the stainless steel pipes it should be removed us ing a hard brush and citric acid do not use a steel brush Always vacuum any dirt away h If deposits have built up on the fan blades carefully clean the blades one by one until the blades are clean again Work consistently in cleaning the blades or else the fan may run irregularly and become out of balance i Carefully bend the electrode until the gap is correct 4 to 5 mm or replace see page 30 j Check the Boiler combustion and re set if required INSTRUCTI NG THE USER Show the user how to operate the entire system Above all the user should be made familiar with all safety precautions The user should be told that service and maintenance of the WG boiler is required every 12 month
31. n heat is no longer required the pump will continue to run for another 1 minute before it stops The pump for the tank is also activated for one minute every 24 hours The 24 hour cycle starts as soon as the power supply to the boiler is activated 7 6 Cooling of the Boiler To prevent scaling of the boiler the fan in the boiler has a post running time exceeding the over run time of the pump the post running time of the fan is variable depending on the water temperature in the heat exchanger 7 7 Frost protection The boiler has a built in frost protection automatically activating the pump when the boiler inlet water temperature drops below 5 C When the boiler water temperature comes subsequently down to 3 C the burner is ignited This will stop as soon as the water temperature has reached 10 C The above mentioned temperatures relates to the temperature measured with the INLET sensor of the boiler Strebel WG Installation amp Service Manual 12 210806 doc 8 Flue Systems 8 1 General Flue systems must be installed in accordance with the Clean Air Act Consult your Local Authority for guidance and their interpretation to ensure the products of combustion are properly dispersed In the following chapters the drawings show the minimum clearances Important Because flue gases have a low temperature below 80 C the boiler needs to have a high efficiency stainless steel or plastic flue system suitable for condensing bo
32. ncrete base or similar Strebel WG Installation amp Service Manual 5 210806 doc 2 Technical Data Strebel WG Condensing Water Heater Range Table 1 Technical Data WG S WG Water Heater Technical Data Table At this resistance level the boiler remains within the value of the boiler label In the case of higher flue resistances the fan pressure will drop Further information on Page 12 Strebel WG Installation amp Service Manual General Product Identification Number CE 0063 BR3190 Dimensions h x w x d mm 835 x 458 x 485 890 x 458 x 670 Classification II2H3P Gas Appliance Type B23 C13X C23X C33X C43X C53X C63X C83X Type Boiler WG 80 WG 100 WG 120 WG 150 WG 180 Water content etc Litre 5 6 5 8 3 10 4 12 9 Weight empty Kg 67 71 77 84 93 In and outlet water connection union inch 1 1 2 2 2 2 2 Gas connection inch R 34 R 34 R 34 R1 R 1 Flue duct flue air inlet concentric mm 80 125 100 150 100 150 100 150 100 150 Power consumption Watt 170 170 170 250 250 Protection class IP40 IP40 IP40 IP40 IP40 Hot water supply Nominal input Net 80 609C kw 15 74 3 17 2 92 2 22 111 2 20 138 25 166 Nominal input Gross 80 609C kw 16 82 19 102 24 124 22 153 28 184 Gas flow max G20 m3 hr 7 9 9 8 11 8 14 7 17 6 Efficiency at 80 60 C High Fire 95 95 95 96 96 Efficiency 50 30 C Low Fire 109 109 109 5 1
33. of the fan cable to the fan when the burner has been pulled half way from the combustion chamber Check the inside of the heat exchanger k Dismantle the air gas mixing box on the suction side of the fan and check the fan blades I Check the distance from the electrode to the burner there should be 4 to 5 mm gap mi Fig 3 Distance from electrode to S CB burner Strebel WG Installation amp Service Manual 30 210806 doc 15 Display Codes On the display when no code is shown e g A3 appears two possible indications 1 A double numbers means the Set Value of the tank temperature when the green led is not lit there is no heat demand when the green led is lit there is heat demand and the boiler is active flames on the burner 2 A blinking dot a the right bottom means the boiler is set for cascade function Display codes without the green LED lit Burner When a code is displayed and the green LED is not lit it means that there is a heat demand but the boiler is temporarily out of order commonly because the temperature is higher than the set temperature After cooling down the appliance will automatically restart and function Status Codes without Lockout lamp illuminated Outlet temperature too high Wait until temperature is decreasing Speed of the fan is too high NE NEN Wait until the speed is OK Speed of the fan is too low Water flow through boiler too low Wait until gradient is
34. ok High limit thermostat is active n a PF Wait for cooling down Power limitation 5096 after too many gradient blockings 8 Call your installer Error Codes Lockout Status with lamp illuminated As the burner control goes into Lock Out the display will show a blinking code which corresponds with the cause of the error the table below shows the errors The boiler can only be re activated by pressing the Reset button CEI RN NN I RN RN CEE 8 NE ETTI NU RN Burner control in not working correctly Limit temperature or problems with the wiring to the gas valve Strebel WG Installation amp Service Manual 31 210806 doc 9 LONG TERM SHUTDOWN It is recommended to leave the boiler turned on all year round to prevent frost damage in winter and mov ing parts seizing due to corrosion during other times of the year If the boiler has to be put out of operation the following action must be taken LONG TERM SHUTDOWN e Close the gas cock e Remove the electrical plug from the wall socket or switch off the mains power e In the event of possible frost damage drain both the calorifier and the system When draining the boiler drain the system first Then open the two drain cocks of the boiler Put the O I switch to position O and the On OFF switch in position OFF e Isolate at local isolation e Open the filling and drain valve of the system and the boiler drain valve on the right hand
35. ot exceed the value limits Try to reprogram 64 Check the supply voltage using a universal meter if the voltage is correct should be between 190 and 250 Volt replace the burner control 65 In order to restore the Reset key take the display from the plastic spacers and try the proper working again If negative replace the display If the display works outside the boiler check that the key has sufficient space under the plastic cover not being blocked make room If the letter H is not blinking replace the burner control 66 Re adjust the gas valve as per the instructions Strebel WG Installation amp Service Manual 37 210806 doc 22 Maintenance Depending on the outcome of the inspection preventative maintenance should be considered as follows a Comments and notes from the customer should be taken seriously and an effort should be made to find the cause of any deficiencies and problems b The pressure of the system should be set between 1 and 6 bar Find possible leaks in the system and have these fixed Flue Find the cause of any water leakage from the air supply possible cause from the roof surface Check both the twin pipe and or the coaxial flue and trace any leaks in the flue gas discharge and rectify C Rinse if the condensed water from the siphon if it is badly contaminated Two further options are available If the burner has already been removed using a filling hose pour water into the heat ex changer it wi
36. ot exceeding 60 kW e BS 6880 Code of practice for low temperature hot water heating systems for output greater than 45 kW e BS6891 Installation of low pressure gas pipework of up to 28mm in domestic premises e BS7206 Specification for unvented hot water storage units and packages Failure to comply with these regulations could lead to prosecution and deem the warranty invalid This appliance must be installed in accordance with the rules in force and in particular in relation to flueing and ventilation 1 3 Health and safety regulations 1993 It is the duty of manufacturers and suppliers of products for at work to ensure so far as is practicable that such products are safe and without risk to health when properly used and to make available to users adequate information about their safe and proper operation Strebel products should only be used in the manner and purpose for which they were intended and in accordance with the instruction in this manual Although the appliances have been manufactured with consideration to safety certain basic precautions specified in this manual must be taken by the user 1 4 Legionella Particularly in health care facilities where occupants are significantly more susceptible to infection a outbreak of Legionnaires Disease have been associated with water systems in buildings A Code of Practice for the Control of Legionella in Health Care premises has been issued by the Department of Health 1991 Also
37. outlet pipes from the boiler to the tank can occur and therefore the control of the boiler is equipped with a sensor to help prevent scaling up which could lead to Boiler damage This sensor activates a service code in the display showing that the system has to be cleaned or flushed with chemicals Water treatment is normally not recommended up to a water hardness of 300ppm 20 degrees Clark because the boiler has a control system for the heat exchanger which reduces this scaling up effect It is advisable to drain the system once every 12 months to take away the debris at the bottom of the tank With water hardness of over 300ppm the risk of scaling up can be minimised by reducing the water temperature setting to less than 55 C or by fitting suitable water treatment equipment Strebel WG Installation amp Service Manual 10 210806 doc 7 3 Condense water drain The condensed water drain is in the centre at the bottom of the boiler and has a inch hose discharge Connect this flexible hose to the sewer system by means of a tundish Important Use only plastic parts with the condensed water drain metal lines are not allowed Tip Blockage of this drain may cause damage to the boiler The drain connection is correct when the condensed water can be seen flowing away e g using a funnel Any damage that may occur is not cov
38. s or more Regular service is essential for the safe operation of the water heater Hand the user the documents supplied with the WG boiler Strebel WG Installation amp Service Manual 38 210806 doc COMMENTS Modulating boiler including controlling for the complete not Secondary Pump hot water system o Non return valve in the flue gas outlet to reduce heat loss Tank of Stainless Steel Bronze pump s Non return valve in the inlet to the boiler to avoid thermo siphon cooling e All Boiler piping in Stainless Steel T amp P relief valve included Complete wiring e Drain valve at the bottom of the tank e Siphon drain hose Cover plate in front of the piping and pumps 6 1 Introduction Warning For good operation of the boiler and to be assured of the warranty of the boiler the following items should be considered 1 The water hardness should not exceed a hardness of 300 mg 20 degrees Clark 2 Minimum static water pressure should be more than 0 5 bar Read the instructions before installation to ensure that all work is done correctly Keep these instructions together with the user manual near the Strebel boiler for quick reference STREBEL Ltd is not liable for any damage caused by inaccurately following these instructions Only STREBEL Ltd parts may be used when carrying out any repair or service works Strebel WG Installation amp Service Manual 39 210806 doc Strebel Ltd 1F Albany Park Industr
39. s the flue resistance increases over 200 Pa N B Install the horizontal parts under 1 fall in the direction of the boiler one centimetre for every linear meter Failing to do so may result in water from the condensation building up in the flue gas tube In turn this may cause failure 8 5 The impact of the outlet to the load The table on the left shows the relation between the load and the resistance of the inlet and the outlet of the system 8 6 WG resistance table The load of the boiler is affected by the resistance of the air inlet and outlet system as a result of gas air coupling in the controls of the boiler At a resistance up to 200 Pa for the WG35 and WG55 the load will be as indicated on the Identification Plate of the boiler Flue Components Resistance Table Item WG35 150 WG 35 230 WG55 230 0 wm fef N N s mu N N O E Flue gas straight tube m iE 4 5 3 Be fof E SS f a 5 N B Example of how to use these resistances shown on Page 18 Strebel WG Installation amp Service Manual 17 210806 doc 8 61 Example calculation Boiler type WG 55 Coaxial Flue System 80 125 Length of flue run from the boiler to the roof terminal 25 meter No of 90 Bends required for the installation 4 pc Calculation 90 Bends 4 pieces 4 x 10 40 Pa 45 Bends 2 pieces 2x5 10 Pa Straight tube 10 m 10 x 10 100 Pa Roof terminal 13 Pa Total Resistance of Flue Components 163 Pa
40. ted pump s on the flow pipe of the boiler directly pumps the domestic water out of the bottom of the tank The water is heated up by the boiler and is carried back to the bottom of the tank During hot water draw off from the tank cold water enters the tank at the bottom directly opposite the flow pipe of the boiler this cold water and a proportion depending on draw off of the water from the tank is mixed inside the tank then fed into the inlet of the boiler The inlet temperature of the boiler is vari able the more water that is drawn off the lower the inlet water temperature will be The outlet water temperature of the boiler which is sent to the tank has a temperature sufficient for maintaining the outlet temperature of the tank constantly at the set hot water temperature The boilers burner modulates on the basis of the hot water outlet temperature of the tank and when no water is drawn off the boiler modulates on the basis of the water temperature inside the tank until the set water temperature has been reached During draw off the inlet temperature is as low as possible therefore the boiler can condense giving an efficiency of over 105 A safety control stops the boiler firing when the water volume through the boiler creates a higher than 17K delta T Strebel WG Installation amp Service Manual 9 210806 doc 7 1 Water quality and treatment In hard water areas scaling of the heat exchanger of the boiler and also in the
41. the entire system in the event of such overall de aeration it is recommended to remove the 230 V off the boiler from the wall switch as the CH pump should not be activated during the process 24 25 Check the air inlet and flue lines for blockage 26 Check the inlet and flue system 27 See 26 28 29 REPLACE THE BOILER 30 Replace the high limit thermostat by unscrewing from the brass nut no draining is needed do not remove the brass nut 31 Go over the settings as outlined Strebel WG Installation amp Service Manual 36 210806 doc 21 REMEDIES Cause No Remedial Action 34 Remove the burner control from the boiler by a Removing the ignition cable from the electrode and remove the cable from the console b Removing the wiring from the spiral 1X2 pole plug 1X8 pole plug and the 230V plug right side of the front Unscrew the facia 4x remove the burner control and replace it 35 Replace when bending take care as bending near the burner plate may give a risk of cracking 36 Dry using a hairdryer as necessary and check if working Replace as necessary 37 See 36 38 See 36 Remove the connection and blow dry using a hairdryer 39 See 36 Remove the connection and blow dry using a hairdryer 40 The plug wire connection must point to the outside of the fan and one side should fit into the groove on the PCB 41 Check plugs and fit into one ano
42. ther correctly 42 Check cables for possible damage or being trapped and replace as required 43 Check connections or replace sensor 44 Check the seal of the heat exchanger on the flue gas casing and replace as required fit a new rotary lip seal 45 Check flow and DHW Pipes 46 Turn the pump switch to position 3 47 Check if the sensors are interchanged 48 Possibly replace the fuse must be a reason for the defect there is no spare fuse present see diagram on page 24 49 Possibly replace fuse must be a reason for the defect there is no spare fuse present see diagram on page 24 50 Check the mains lead the wall box for voltage main fuse 51 Check the programmed parameters 52 53 Change the pulse width program see parameter manual 54 Change the start up times of the clock 55 Flow is on the left hand side of the boiler return on the right hand side 56 Check the connection strip 57 Check the sensors 60 It may occur that the 18 pin PCB plug moved up one pin too far this may cause a fault in the communication between the wiring and the pins check both the left and the right hand side of the PCB plug to make sure the plugs are placed correctly 61 A defect to the gas block usually has one of two causes the electric coils are defective or an internal defect on the gas valve In either case it would be recommended to replace the entire gas valve 63 Use the correct software please check for programming Also do n
Download Pdf Manuals
Related Search