Coopra 40C User manual

EN
Installation Manual
Heating Boiler . . . Type 40C
Wall hung, fan flue, room sealed gas boiler
CHAPTER 1. GENERAL
CHAPTER 2. INSTALLATION
CHAPTER 3. SUSPENDING THE UNIT
CHAPTER 4. COMMISSIONING
CHAPTER 5. TEMPERATURE REGULATIONS
CHAPTER 6. BURNER STATES and MONITORING
CHAPTER 7. MAINTENANCE
CHAPTER 8. MALFUNCTIONS
CE-CERTIFICATE
2007 E000129032

Coopra Advanced Heating Technologies Installation manual 40 EN
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CONTENTS
CHAPTER 1. ………………………………………………………………………………..……….……………………………4
1.1. Technical data
1.2. Dimensional sketch…………………………………………………………………………………..……………………. 5
1.3. Unit components……………………………………………………………………………………………….…………… 6
1.4. Diagrams
1.4.1. Functional flow diagram………………………………………………………………………………….…… 7
1.4.2. Wiring diagram………………………………………………………………………………………...……….. 8
1.5. Operation………………………………………………………………………………………………………………..….. 9
1.6. Boiler types
1.6.1. Burner assy
1.6.2. Primair heat exchanger
1.6.3. Venturi
1.6.4. Pump
1.7. Conditions of delivery
1.8. Configuration of flue tube and air supply………………………………………………………………………………… 10
1.9. Environmental conditions
1.10. Permitted flue resistance
1.11. Heating of central heating water
1.12. Pump and hydraulic resistance…………………………………………………………………………………………. 11
1.13.
1.14. Standards / Guidelines
1.15. General safety regulations
1.16. Water quality
CHAPTER 2. INSTALLATION…………………………………………………………………………………………….…… 12
2.1.
2.2. Mounting the assembly bracket
2.3. Water and gas connections………………………………………..…………………………………………………….. 13
2.4. Seal on the waterside
2.5. Draconin connection
2.6. Electricity connection
CHAPTER 3. SUSPENDING THE UNIT ………………………………………………………………………………..……. 14
3.1. The unit
3.2. Suspension
3.3. Fitting the flue tube and air supply
3.3.1. Connecting the eccentric flue and air supply (2-pipe system)
3.3.2.
3.3.3. Connecting the concentric flue tube and air supply (60/100 mm adapter)
3.4. Condensation water drain/overpressure protection on drain
3.5. Connection block
3.5.1. On/off room thermostat (if applicable).
3.5.2. Modulating room thermostat (if applicable)………………………………………………………….………. 15
3.5.3. Connection for the external temperature sensor (if applicable).
3.6. Assembling the connection block
3.7. Placing the jacket
CHAPTER 4. COMMISSIONING…………………………………………………………………………………………..….. 16
4.1. Electrical connection 230 VAC
4.2. Main switch
4.3. Filling
4.4. Reading the water pressure
4.5. Venting
4.6. Chimney sweeper function
4.7. Gas / Air Ratio
4.8. Gas / Air adjustment ( CO2analysing)…………………………………………………………………………..……….. 17
4.9. Placing the jacket
4.10. Changing over to LPG-gas……………………………………………………………………………………….....….. 18
4.11. Display……………………………………………………………………………………………………………….…….. 19

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4.12. Menu structure……………………………………………………………………………………………………………. 20
CHAPTER 5. TEMPERATURE REGULATIONS……………………………………………………………………….……. 21
5.1. Central heating
5.1.1. Central heating temperature regulation with on/off thermostat without outside temperature sensor
5.1.2. Central heating temperature regulation with on/off thermostat with outside temperature sensor
5.1.3. Central heating temperature regulation with modulating thermostat (Opentherm)……………………. 22
CHAPTER 6. BURNER STATES and MONITORING……………………………………………………………..……….. 23
6.1. Standby
6.2. Pre rinse
6.3. Ignition
6.4. In operation
6.5. Post-rinse………………………………………………………………………………………………………….………… 24
6.6. Lock-out
6.7. Pump test program
6.8. System pressure monitoring
6.9.
6.10. Temperature regulation
6.11. Limiter
6.12. Flue sensor………………………………………………………………………………………………………...……… 25
6.13. Frost protection
6.14. Glow plug protection
CHAPTER 7. MAINTENANCE……………………………………………………………………..………..………………… 26
7.1. ANNUAL MAINTENANCE
7.1.1. Checking the CO2percentage on full load
7.1.2. Measuring the load on the unit
7.1.3. Checking the condensation water drain
7.1.4. Ionisation probe
7.1.5. Water pressure
CHAPTER 8. MALFUNCTIONS……………………………………………………………………………………………….. 27
8.1. Draining the unit
8.2. No signal on the display
8.3. Fault code 'U/d or U/O' (alternating U with a status code will appear on the display)
8.4. Unit does not respond to central heating heat demand
8.5.
8.6.
8.7. Check function of gas control
8.8. Measuring the fan impedance
8.9. Fitting instructions for the pressure sensor
8.10. Fitting instructions for the safety valve
8.11. Malfunction code 'F' (flashing)............................................................................................................................. 28
8.11.1. Gas control will not open (no voltage)
8.11.2. Gas control will not open (gas inlet pressure too high)
8.11.3. Gas control will not open (coils defective)
8.11.4. Gas/air mixture is not correctly adjusted
8.11.5. Check glow plug
8.11.6. Check ionisation current
8.11.7. Inspection / cleaning / replacement of the ionisation probe
8.11.8. Ionisation probe or ionisation cable makes short circuit with earth
8.11.9. Boiler pump
CE-CERTIFICATE…………………………………………………….…………………………………………………………. 30

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CHAPTER 1.
1.1. Technical data
Boiler type 40C
Gas type natural gas G20 LPG gas G30/G31
Mains voltage / Frequency 230 V / 50 Hz
Power consumption (max.) 144 W
Electrical data
Thermostat voltage 24 V
Height 600 mm
Width 360 mm
Depth 300 mm
Dimensions and
weight
Weight 35 kg
CO28.2% - 8.8% 9.2% - 9.8%
CO (0% 02) 12 – 100 ppm
Emission value
NOX(0% O2) 10 – 30 ppm
at 80/60ºC < 70ºC
Flue gas-
temperature at 50/30ºC < 35ºC
Maximum
chimney
resistance
Air feed and flue tube together 125 Pa
Gas Ø 15 mm
CH (flow and return) Ø 20 mm
Connections
Overflow Ø 15 mm
Eccentric Ø 60 – Ø 60 mm or Ø 80 – Ø 80 mm
Air feed and flue
tube system Concentric Ø 60 / 100 mm or Ø 80 / 125 mm
Water contents 0.8 L
Max. temperature 90°C
Boiler heat
exchanger
Max. Water pressure 3 bar
Pump high 40 dB(A)
Sound level
Pump low 30 dB(A)
Certification CE Identification number CE0063-AT3070
Boiler type 40C
Gas type natural gas G20 LPG gas G30/G31
Nominal gas pressure 20 mbar 37/50 mbar
Heat input CH (gross) 8.1 – 41.1 kW
Heat input CH (net) 7.3 – 37.0 kW
Nominal output CH at 80/60ºC 7.2 – 36.0 kW
Nominal output CH at 50/30ºC 7.9 – 37.9 kW
Efficiency at 80/60ºC (net) Low load = 98.1 %; High load = 97.2 %
Gas technical
data type 40
Efficiency at 50/30ºC (net) Low load = 108.4 %; High load = 104.2 %

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1.2. Dimensional sketch
Dimensions in mm
Free space
There must be sufficient space at the top and bottom to be able to suspend the unit and to be able to connect all feed and drain
pipes. Normally, roughly 300 mm is required.
It is recommended to leave a free space of 150 mm on the left (for servicing reasons) and 50 mm on the right of the unit.
The front of the unit must be easily accessible for servicing at all times.

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1.3. Unit components
No Description Manufacturer
1 Primary heat exchanger Coopra
2
3 Pump Wilo
4
5
6 Glow plug Saint Gobain
7 Ionisation probe Sapco
8 Burner type 30 / 40 Furigas
9 Vapour tray Coopra
10 Gas valve Honeywell
11 Fan Vibo
12 Venturi type 40 Honeywell
13 Water pressure sensor Huba
14 Return sensor Honeywell
15 Flow sensor Honeywell
16 Safety device 3 bar Model 2000 Emmeti
18 N/A N/A
19 Flue gas temperature sensor Tasseron
20 Type plate Coopra
21 Condensation water overflow Coopra
22 Gas connection Coopra
23 Central heating return
24 Central heating flow

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1.4. Diagrams
1.4.1. Functional flow diagram
F1
L
F2
N
+
-
FSP
-t
-t
-t
-t
-t
-t
BURNER
FLOW X17.6
X7.1
X7.2
X7.4
X14
X6.4
X6.1
X12
X8.6
X8.2
X4.4
X3.5
X3.4
X3.2
X3.1
X22.2
X22.1
X4.6
X4.5
X4.3
X4.1
X8.5
X8.4
X8.3
X8.1
X6.3
X9.2
X1.3
X10.2
X11.2
X9.1
X1.4
X10.1
X11.1
X16.7
X16.6
X16.3
X16.2
X15.2
X15.1
X15.3
X18.1
X18.3
X17.5
X19.1
X17.2
X19.2
X17.3
ROOM THERMOSTAT
24VAC
ROOM THERMOSTAT
230VAC
EbV THERMOSTAT
OPENTHERM
THERMOSTAT
PC CONNECTION
FLUE GAS
OUTSIDE
WATER PRESSURE +
P
-
RETURN
DHW INLET
EXTERNAL TANK
TANK THERMOSTAT
GLOW IGNITER
LN
IONISATION
GAS VALVE
230 VRAC
COMBUSTION FAN
325 VDC
ALARM CONTACT
MAXIMAL THERMOSTAT
(OPTIONAL)
DISPLAY
PE
230V 50 Hz N
L
FURIMAT-990
PE
PE
PE
DHW
CH
N
PE
PE
L1
L3
L2
N
X2.5
X2.4
X2.2
X2.1
X2.3 PUMP 230 VAC
PE
THREE-WAY VALVE
230 VAC

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1.4.2. Wiring diagram

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1.5. Operation
A fan sucks the air required for the combustion through the air
feed canal (A). Because the combustion air in the venturi
sucks an under pressure, the correct amount of gas (G) is
automatically added to the combustion air.
The flammable gas/air mixture thus obtained is fed to the
burner, via a mixing chamber, to be ignited at the surface of
the burner by a ceramic glow plug. The hot combustion gases
are efficiently fed through the heat exchanger, where they
give their heat to the water. The flue gases are fed outside,
through the flue tube (F), into a flue tube exhaust canal.
The condensation water (H2O) thus obtained is discharged
into the sewer.
1.6. Boiler types
Coopra 40C
High efficiency boiler for central heating
only.
The Coopra boiler is a heating unit with compact dimensions
and a very high efficiency, with versions for domestic and
small commercial use for central heating.
The type plate, which specifies the type of gas etc. to be used,
for which the unit is set, is on the left side of the unit.
The unit is fixed to the wall with the aid of a separately
delivered assembly bracket or rear cabinet.
1.6.1. Burner assy
1.6.2. Primair heat exchanger
1.6.3. Venturi
1.6.4. Pump
1.7. Conditions of delivery
Coopra Advanced Heating Technologies b.v. supplies its
products according to the general conditions of delivery for the
metal and electro technical industry. Registered with the Clerk of
the District Court at Den Haag on 19 October 1998 under no.
119/1998.

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1.8. Configuration of flue tube and air supply
See figure below for an overview of possible configurations.
The units are approved for application on the drain systems:
B23, C13(x), C33(x), C43(x), C53, C63(x), C83(x).
Preferably use flue tube materials, roof ducts and exterior wall
ducts with a quality mark.
With plastic drain materials, use a unit with a flue gas
temperature sensor.
1.9. Environmental conditions
The area in which the unit is installed must satisfy the
applicable regulations.
The wall must be able to bear the weight of the unit (loaded
weight approx. 40 kg).
If you use a different assembly surface than a bricky wall of
sufficient thickness, you must select suitable fixtures yourself
and properly install the unit.
The unit may not be fitted in a chemically aggressive
environment.
The unit with air feed and flue gas exhaust satisfies the
requirements of protection class IP44 and may therefore be
installed in a wet area.
Although the unit is fitted with an internal frost protection, it
may not be exposed to extremely low ambient temperatures
(lower than -10°C).
1.10. Permitted flue resistance
Indication for the resistance values given in table below apply
to -Flue exhaust flow rate of 61 m3/hour (at 70 ‘C)
-Supply air flow rate of 48 m3/hour (at 20 ‘C)
The total resistance of the flue tube and air supply together
may not be greater than 85 Pa.
Ø 100 mm Ø 80 mm
Type 40 (35)
Tube per metre 2,5 Pa 5.0 Pa
Bend 90°, R = 1.5 D 3.0 Pa 6.0 Pa
Bend 90°, R = 0.5 D 5.0 Pa 10.0 Pa
Bend 45°, R = 1.5 D 2.0 Pa 4.0 Pa
Bend 45°, R = 0.5 D 3.5 Pa 7.0 Pa
Roof duct 20.0 Pa 30.0 Pa
1.11. Heating of central heating water
If the room thermostat or space unit indicates that heat is
required for the central heating, the unit will heat the central
heating water as necessary. The power supplied is
automatically adapted to the heat required and is also
continuously variably adapted to the heat demand with the
use of an on/off thermostat.
When the thermostat indicates that the desired temperature
has been reached, the central heating water is no longer
heated. The central heating pump will continue to run for a
previously set time to distribute the heat evenly over the
heating installation.
A differential bypass valve must be installed on plants where it
may happen that various radiators are simultaneously
excluded from the circuit because of closure of control or zone
valves.
The by-pass valve must be mounted in the installation
between the flow and the return, provided that flow direction
indicated by arrow is respected.
To adjust the by-pass valve rotate knob of the graduated
scale on setting 2.5-3.0. This value corresponds to the meters
of pump head (m H2O).
Lock the screw on the groove knob.

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1.12. Pump and hydraulic resistance
The pump characteristic and the resistance graph of the unit
are given below.
If set on automatic function (menu setting) the electronics
switches the speed of the pump to “high” or “low”, depending
on the temperature demand:
•Dt > 30 °C : the pump runs „high speed“.
•Dt < 10 °C : the pump runs „low speed“.
Dt = Setpoint temperature deducted with the actual Flow
temperature.
1.14. Standards / Guidelines
With the installation of the unit, all local regulations must be
followed, where applicable, including the provisions of the
following standards and guidelines:
•Building Regulations
•Regulations for natural gas installations
•Regulations for LPG (if applicable)
•Guidelines for existing gas installations
•Safety requirements for central heating installations
•Safety provisions for low voltage installations
•General regulations for drinking water installations
•Water authority regulations
•Ventilation in dwellings
•Supply of combustion air and exhaust
•House sewerage in homes and dwellings
•Fire Brigade regulations
•Factory Act regulations
•Regulations applicable to HWS water Ask for the
locally applicable regulations at the local water
company as they are different in some areas
1.15. General safety regulations
The installation may only be performed by a recognised
installer.
Take note that internal parts of the unit can carry a dangerous
electrical voltage (230 Volt).
Take note that the unit, the various pipes and the flue gas
exhausted by the unit can reach high temperatures (up to
90°C).
Before carrying out maintenance activities in or on the unit,
you must close the gas tap, switch off the electricity supply
and pull the mains plug out of the socket.
1.16. Water quality
The composition and quality of the system water has a direct
effect on the performance of the total system and the life of
the boiler heat exchanger. Great care must be used with the
addition and use of chemicals, water softeners, oxygen
binders, de-aerators, aerators and water filters as they
increase the chance of malfunctions.
Corrosive elements of certain additives can attack the system
and cause leakages; the build-up of undesired deposits
generally leads to fatal damage of the heat exchanger.
00,2
0
0,2
0,3
0,6
Flow [m³/h)]
Pressure [bar]
0,7
0,5
0,4
0,1
0,4 0,6 0,8 1,0 1,2 1,4 1,6 1,8 2,0
Pump state high
Pump state low
Boiler resistance
2,2 2,4 2,82,6 3,0
0,8

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CHAPTER 2. INSTALLATION 2.2. Mounting the assembly bracket
To mount the assembly bracket on a brick wall of sufficient
thickness, use the screw plugs that are supplied. When you
have determined the place of assembly, proceed as follows:
1. Draw the position of the hole (1) in the strap of the
assembly bracket.
2. Use a masonry drill of 8 mm diameter to drill a hole with a
sufficient depth in the wall.
3. Keep the hole (1) in the assembly bracket in front of the
hole in the wall and fit one of the screws supplied through
the assembly bracket in the hole.
4. Align the assembly bracket with the aid of a spirit level.
5. Use a masonry drill of 8 mm diameter to drill holes with a
sufficient depth in the wall through the two bottom holes (2)
in the assembly bracket.
6. Fit two of the screws supplied in the bottom holes.
7. When using assembly brackets with ac lamping plate for
eccentric flue tube and air feed connection:
- Use a masonry drill of 8 mm diameter to drill a hole
with a sufficient depth in the wall through the hole in
the clamping plate and fit a nail plug in this hole.
- Fit the clamping plate at right angles.
8.Fix the assembly bracket firmly by tightening all screws.
1
2

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2.3. Water and gas connections
1 = Heating return pipe connection
2 = Heating flow pipe connection
3 = Gas connection
4 = Draconin connection
2.3.1. Gas connection
•Connect the gas pipe to connection (3).
•Install the gas pipe stress free.
•Include an approved stopcock in the pipe.
•Carefully blow the gas pipe clean.
2.3.2. Central heating water connections
•Connect the central heating return pipe to connection
(1). The central heating return pipe (1) must be fitted
with a suitable expansion vessel. The size of the
expansion vessel must be determined on the basis
of the central heating water temperature and the total
water content the installation contains.
•Connect the central heating flow pipe to connection
(2).
•A differential bypass valve must be installed on
plants where it may happen that various radiators
are simultaneously excluded from the circuit because
of closure of control or zone valves.
•Install a filling and draining device in the central
heating system. Do not use the overflow valve as a
drain. The overflow valve is a safety valve that
ensures that the system is not subjected to a too
high pressure (max 3.0 bar).
•Stopcocks must be fitted in the central heating flow
pipe (2) and the central heating return pipe (1).
•If it may be expected that the central heating water will
be severely contaminated by under floor heating, fitting
is a 2 kg dirt filter in the return pipe is recommended.
Coopra cannot give a guarantee for damage to the unit
that is caused by dirt in the system.
•Before connecting the boiler unit, rinse the system
completely to remove all contamination.
2.4. Seal on the waterside
With the use of the group of taps, you can now make a check
on the seal on the waterside of the system.
2.5. Draconin connection
There must be a connection for the removal of the
condensation water to the drain. This connection must be
fitted with a trap to prevent smell problems.
A tundish connection must be made because of possible
overpressure or underpressure in the drain.
Fit the condensation drain pipe (4 (inner diameter 40 mm
minimum) several centimetres left of the gas pipe.
2.6. Electricity connection
There must be an electrical outlet with earth connection
available at a maximum distance of 1 m from the unit.
The electricity connection (230 VAC) must consist of live,
neutral and earth
A good earth connection is a requirement for good operation
of the unit.
321
4
40
75

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CHAPTER 3. SUSPENDING THE UNIT
3.1. The unit Before unpacking the unit, check
whether the type of gas to be used
corresponds with the specification on
the packing. If you have any
questions, contact your supplier.
To prevent back injury, take account
of the fact that the weight of the unit is
roughly 35 kg.
3.2. Suspension
Place an O-ring in the middle of each of the connections
present (1) - (5).
Remove the caps from the pipes of the unit.
Keep the unit straight against the wall at about 5 cm above
the site of the mounted assembly bracket or the assembly
cabinet.
Press the unit into the guide and let it drop carefully, so that
the hook on the suspension bracket falls into the opening at
the rear of the unit and the pins at the bottom of the unit fall in
the corresponding openings in the suspension bracket. Here,
the connection pipes of the unit fall over the connection points
of the suspension bracket.
Firmly tighten the union nuts of each of the connections
present (1) to (5) with the aid of a spanner.
3.3. Fitting the flue tube and air supply
3.3.1.
Connecting the eccentric flue and air supply (2-pipe
system)
When the flue tube and air supply are connected
eccentrically, proceed as follows:
1. Fit the flue tube in the opening, in the suspension bracket.
2. Let the pipe protrude 30 -35 mm under the clamping plate.
Slide the sliding piece (1) upwards over the flue tube.
3. Fit the air supply in the opening in the suspension bracket.
4. Let the pipe protrude 40 - 45 mm under the clamping plate.
5. Fit the rubber bellows over the air supply pipe and seal
them with the hose clip.
6. Fit the clamping plate on the suspension bracket and
tighten it with the three screws supplied. Take care here that
the clamping plate falls in the groove of the sliding piece.
3.3.2. Connecting the concentric flue tube and air supply
(80/125 mm adapter)
When the flue tube and air supply are connected
concentrically, proceed as follows:
1. Fit the 80/125 mm adapter on the unit before you place the
unit.
2. After you have placed the unit, fit the concentric pipes on
the 80/125 mm adapter.
3.3.3. Connecting the concentric flue tube and air supply
(60/100 mm adapter)
When the flue tube and air supply are connected
concentrically, proceed as follows:
1. Fit the 60/100 mm adapter on the unit before you place the
unit.
2. After you have placed the unit, fit the concentric pipes on
the 60/100 mm adapter.
3.4. Condensation water drain/overpressure protection on
drain
Make a tundish between the condensation water
drain/overpressure protection of the unit and the drainpipe.
3.5. Connection block
The connections of the green connection block are all volt-
free contacts. Therefore, do not connect 230 Volts to them!
If no on/off room or modulating room thermostat is used at all,
terminals (1) and (2) must be connected by wire.
terminals (1) - (2) Connection for 24 Volt thermostat
terminals (3) - (4) Connection for 12 kOhm external
temperature sensor
terminals (5) - (6)
3.5.1. On/off room thermostat (if applicable).
Connect to terminals (1) and (2)
The on/off room thermostat (24 V) must be fitted in the same
building as the unit.
Strip about 5 mm off the insulation of the wires of the room
thermostat. Stick the stripped ends of the wires into
connections (1) and (2) of the connection block. Make sure
that the wires do not make a short circuit. Firmly tighten the
screws in the connection block.

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3.5.2. Modulating room thermostat (if applicable).
Connect to terminals (1) and (2)
The modulating room thermostat must be fitted in the same
building as the unit.
Strip about 5 mm off the insulation of the wires of the room
thermostat. Stick the stripped ends of the wires into
connections (1) and (2) of the connection block. Make sure
that the wires do not make a short circuit. Firmly tighten the
screws in the connection block.
When using a modulating thermostat, the plug on the printed
circuit board must be connected with the correct polarity.
To reach the printed circuit board, the black casing must be
opened. Connect the plug for the relevant modulating space
unit to terminal a, b or c, according to the following
photograph.
a White Connection for an on/off
room thermostat 24 Volt
b Red Connection for RS30 with
Coopra protocol EBV space regulation
c Blue Opentherm connection Honeywell or TEM
space regulation
3.5.3. Connection for the external temperature sensor (if
applicable).
Connect to terminals (3) and (4)
If an external sensor is connected, this temperature sensor
must be an NTC with a resistance of 12 kOhm at 25°C.
Strip about 5 mm off the insulation of the wires of the sensor.
Stick the stripped ends of the wires into connections (3) and
(4) of the connection block, see figure 8. Make sure that the
wires do not make a short circuit. Firmly tighten the screws in
the connection block.
If an external sensor is not used, terminals (3) en (4) can
remain open.
3.6. Assembling the connection block
Connect the green connection
block in the green socket.
3.7. Placing the jacket
Place the jacket in the appropriate hooks at the top of the unit.
Let the jacket pivot until it falls over the unit. Tighten the
fastener at the bottom of the jacket.
b
a
c

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CHAPTER 4. COMMISSIONING
4.1. Electrical connection 230 VAC
•If the boiler is provided with a supply cord and a plug the
appliance must be positioned so that the plug is
accessible.
•If the boiler is not provided with a supply cord without a
plug the supply must have a contact separation of at least
3 mm in all poles.
If the supply cord is damaged, it must be replaced by the
service agent or similarly person in order to avoid a hazard.
4.2. Main switch
To power up the appliance
please switch the main switch
on.
If the display of the unit gives
the status code ‘U’ (alternately
with an arbitrary other code),
this means the live and neutral
connections are reversed. Isolate the supply and reverse the
connections.
4.3. Filling
During filling with water, the unit must be connected to the
mains and be switched on. Fully open all radiator taps.
Connect the water supply to the filling connection. If the unit is
not yet filled with water, the display shows a flashing ‘P’. The
two numbers on the display give the water pressure.
Open the tap to fill the system with water.
When the water pressure is sufficient (> 1.3 bar), the flashing
‘P’ disappears from the display.
Close, after filling, the filling tap again.
4.4. Reading the water pressure
It is possible to read the water pressure directly from the
display. To do this, press the + button of the display for a
minimum of 5 seconds.
The unit switches out of the menu back to normal operation:
•automatically after about 5 minutes;
•or if you press the - button of the display shortly.
4.5. Venting
After filling, the heating installation must be vented.
Proceed as follows:
Follow the instructions from the manufacturer/installer for the
venting of possible other elements of the heating installation,
such as underfloor heating.
Fully open all radiator taps.
Open the air bleed cocks of the radiators one at a time. Use
an air bleed key for this.
As soon as water comes out of the air bleed cock, shut the
cock off again.
4.6. Chimney sweeper function
The chimney sweeper function has priority over the central
heating and HWS regulation.
The chimney sweeper function is
activated by simultaneously
pressing the "+ and the –
buttons" of the display in for
longer than 5 seconds.
The ionisation current can be read in microamperes in the two
right segments.
The capacity that is immediately released is the maximum
central heating capacity.
Press the "- button" to go
to low load.
Press the "+ button" to
switch back to the preset full
load capacity.
4.7. Gas / Air Ratio
(1). Venturi screw – Full load adjustment
Turn the venturi screw anti-clockwise to increase the CO2
value, clockwise to decrease it.
(2). Gas control screw – Low load adjustment
Turn the screw anti-clockwise to decrease the CO2value on
low load, clockwise to increase it.
(3). Cover screw

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Pre-adjustment to be done in voltage-free condition:
-LPG GAS – Turn venturi-screw clockwise 3
completely down on its seat.
Then turn the venturi screw anti-clockwise 4for
1/2 complete turns.
-NATURAL GAS – Turn venturi-screw clockwise 3
completely down on its seat.
Then turn the venturi screw anti-clockwise 4for
3 complete turns.
With a vernier callipers the distance between venturi-screw
(1) and the Top of the venturi-stud (1) has to be measured to
find the rough setting of the venturi screw for full load, and
depending of the used gastype.
The exact adjustment of the setting has to be made using the
CO2analysing method as described below.
4.8. Gas / Air adjustment ( CO2analysing)
The gas control is set in the factory to the type of gas to be
used. This type of gas is stated on the packing and on the
identification plate. To check the setting, you have to make a
flue gas analysis.
Proceed as follows Remove the measuring cap
from the flue tube.
Fit the measurement probe of a
flue gas analyser (CO2meter)
in the measurement opening of
the flue tube canal.
Make sure there is sufficient
heat dissipation through the
heating.
CO2setting At full central
heating load
(P=100%)
At low load
Natural gas
(G20, G25)
8,8 % CO28,2 % CO2
Propane (G31) 9,8 % CO29,2% CO2
4.8.1. Full load
The burner has to burn at maximum central heating capacity
(Menu setting P=100%).
Activate the chimney sweeper function on full load.
Read the CO2value on the
analyser. If the value does not
correspond with the value in
the "CO2setting" table,
carefully adjust the venturi
screw (1). Turn the venturi
screw anti-clockwise to
increase the CO2value,
clockwise to decrease it.
4.8.2. Low load
Activate the chimney sweeper function on low load
Read the CO2value on the
analyser. If the value does not
correspond with the value in
the "CO2setting" table,
carefully adjust the gas control
adjusting screw (2). To do this,
temporarily remove the cap (3)
with the aid of a Torx
screwdriver. Turn the screw
anti-clockwise to decrease the CO2value on low load,
clockwise to increase it.
At the end of the flue gas analysis, set the central heating
capacity (P) in the menu again to the value that is best suited
for the application.
4.9. Placing the jacket
Place the jacket in the appropriate hooks at the top of
the unit. Let the jacket pivot until it falls over the unit.
Tighten the fastener at the bottom of the jacket.
PRE- ADJUSTMENT MEASUREMENT:
Distance between Venturi-screw (1) and the Top of the
venturi-stud to be about:
912 mm for natural gas G25
914 mm for natural gas G20
916 mm for LPG gas G31

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4.10. Changing over to LPG-gas
First: the venturi adjusting screw fully clockwise until it
blocks.
Fit a flue gas analyser (CO2
meter) in the measurement
opening of the flue tube canal.
Full load on LPG
Activate the chimney sweeper function on full load.
Turn the venturi adjusting
screw fully clockwise until it
blocks.
Unscrew the venturi adjusting
screw half a full turn anti-
clockwise. Try to start the
appliance.
Unscrew the venturi adjusting
screw another half a full turn
anti-clockwise. Try to start the appliance.
Repeat till the boiler starts.
(A guide for the dimension from the top of the screw to the top
of the support is 16 mm).
Read the CO2value on the flue gas analyser. If the value
does not correspond with the value for propane gas G31
(9,8% CO2), carefully adjust the venturi screw until the correct
value is obtained.
Low load on LPG
Activate the chimney sweeper function on low load.
If the gas control is already
properly adjusted for natural
gas, then the low load will not
need to be adjusted.
If necessary, adjust the gas regulator screw until the correct
value ((9,2% CO2) is obtained. Note that this setting is critical
to adjust.

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4.11. Display
A = display
B = + button
C = Set / Reset
D = Status display
E = - button
During operation, the display shows the status of the unit in
the form of a code. To be able to read the codes, open the
cover in front of the display. The display consists of three 7-
segment LED’s + three decimal points and three pushbuttons.
The left 7-segment LED shows the status or the menu step.
The two right 7-segment LED's show the temperature, the
pressure or the parameter value.
4.11.1. Normal operation (permanent status indication)
The Normal operation is to indicate the burner action.
- - Initialisation after restoration of supply power
O No heat demand, stand-by
C Central heating heat demand, burner off
C. Central heating heat demand, burner on
P/C. Central heating heat demand, low load water pressure
A/C. Central heating heat demand, low load chimney temperature
c Central heating pump post-running
b Burner off / post-running of pump for external HWS cylinder
b. Burner on
P/b. Boiler, low load by water pressure
A/b. Boiler, low load by chimney temperature
O Frost protection burner off pump running 8C
o. Frost protection burner on 3C
C (flashing) Chimney function (temp display max/min/ionisation)
4.11.2. Blocking operation (permanent status indication)
The burner stopped burning due to an incorrect situation. The display gives a permanent indication (not flashing) and the
operation can be restored by switching it off and on (volatile block).
U/
code Reversed neutral and line Power supply line not correctly connected
1 Flow sensor open circuit Faulty flow sensor
Wiring interrupted or not correctly connected
1. Flow sensor short circuit Faulty flow sensor
Faulty wiring
2 Return sensor open circuit Faulty return sensor
Wiring interrupted or not correctly connected
2. Return sensor short circuited Faulty return sensor
Faulty wiring
4 Flue gas sensor open circuit Faulty flue gas sensor
Wiring interrupted or not correctly connected
6 Cold water sensor open circuit n.a.
6. Cold water sensor short circuited n.a.
A Flue gas temperature > 80°C The burner is reduced to low load
H Flow sensor > 105°C while the burner was off Reset the supply power by the on/off switch
E Internal error Reset the supply power by the on/off switch
P Pump test / Start function blocking / Water pressure Check the central heating system pressure
Seized or faulty pump or faulty pump wiring
Faulty pressure sensor or wiring
nc Burner Manager fault Reset the supply power by the on/off switch
4.11.3. Lock-out (flashing status indication)
In case of lock-out the display gives a flashing indication and the operation can be restored by pressing the reset button, placed
on the control panel.
1 Boiler does not pass start temperature test Check system water flow; second system pump
2 Too many restarts
3 Internal regulation fault / A/D conversion fault /
external sensor fault /Too many restarts
5 Fan fault
7 Gas valve fault
8 Flame detected with closed gas valve Check gas valve
A Flue gas temperature > 95°C Check why flue gas becomes temperature > 95°C
E Internal interlock fault Reset the supply power by the on/off switch
H Flow sensor > 105°C with burner on Check system water flow
F Too many ignition attempts
O Gas valve connection Check short cut wire on printed circuit board terminal X4

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4.12. Menu structure
By pressing the set/reset button in for longer than 5 seconds, you go to the ‘mode’ menu.
To change the subsequent "Letter" parameter, the user must press the Set/Reset button.
To change the “Range” setting in the parameter, the user must press the “+” or the “–“ button.
Letter Description Range Factory setting Field of application
C max. set point of central heating 25°C - 90°C 82°C
O Central heating post-running time 1 - 25 min, CO = 24 hours 5 min
P Max central heating capacity 33 – 100 % 80 %
H Type of application
0 = central heating unit
1 = n.a.
2 = for external HWS cylinder 12kOhm
3 = for external HWS cylinder 10kOhm
4 and 5 = all functions are blocked
unit-dependent unit-dependent
d
t
b Set point for storage HWS cylinder 40°C -70°C 60°C external storage
vessel
O/b Basic temperature
External characteristic 10 -70°C 20°C
O/S Slope
External characteristic 1-100 20
O/d Day reference temperature 0°C -70°C 20°C
These three settings
are only active when
an external sensor is
connected
r Factory setting = Factory setting
= Changed factory setting
If you switch back to the factory setting,
this has no effect on the H, S and P/S
settings
S Pump speed
00 = automatic
= always high
= always low
00 = automatic
P/S Maximum pressure jump
= 0.54
= 0.53
= 0.52
= 0.54
In the View mode, you can read the actual values of:
8 = Water pressure (in bar)
1 = Flow temperature (in °C)
2 = Return temperature (in °C)
3 = Inlet cold water temperature / HWS sensor (in °C)
4 = External temperature (in °C)
5 = External cylinder temperature (in °C)
6 = Flue gas temperature (in °C)
7 = Flame signal (in μA DC)
9 = Last interlock
A = Last blocking