Warmco XR Series User manual

INSTRUCTION MANUAL
PREMIX UNIT AIR HEATER
TYPE XR
Production from 2019
THIS DOCUMENT MUST ABSOLUTELY BE READ BEFORE STARTING THE
INSTALLATION.
INSTRUCT USER AND LEAVE THIS DOCUMENT WITH HEATER FOR
REFERENCE.
Date: 01-02-2019
Instruction manual version XR-GB-4001-a
Heaters for GB
heaters for natural gas G20 and Propane

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 2/25
Introduction
This installation and user manual is produced specifically for the gas, electrical and mechanical
installer , it also gives instructions how to use and maintain the heater.
It is most important to follow the directions in this booklet for safe operation of this product.
1Content:
Page
1 CONTENT: 2
2 GENERAL 3
2.1 S AFETY WARNINGS 3
2.2 I MPORTANT CHECKS BEFORE INSTALLATION 3
2.3 G UARANTEE 4
3 TECHNICAL DETAILS: 5
4 INSTALLATION 7
4.1 P OSITIONING 7
4.2 G AS CONNECTION 9
4.3 E LECTRICAL CONNECTION 9
4.4 A IR INTAKE / COMBUSTION PRODUCTS DISCHARGE 10
4.5 I NSTALLATION R OOF OR W ALL TERMINAL 11
5 FUNCTIONING OF THE UNIT 14
5.1 G ENERAL 14
5.2 B URNER CYCLE 14
5.3 D ELTA -T- REGULATION ( TEMPERATURE CONTROLLED DE - STRATIFICATION FAN ) 14
5.4 S UMMER VENTILATION 14
5.5 H IGH LIMIT PROTECTION 15
5.6 F LUE T RANSPORT S UPERVISION 15
6 PUTTING INTO OPERATION AND ADJUSTMENT 15
6.1 G ENERAL 15
6.2 S TART BY USING THE THERMOSTAT 15
6.3 S TART THROUGH THE DISPLAY IN THE HEATER 16
7 ADJUSTING THE GAS-CONTROL 16
8 PROBLEM SOLVING 17
8.1 G ENERAL 17
9 MAINTENANCE / SPARE PARTS 20
9.1 G ENERAL INSPECTION 20
9.2 I NSPECTION OF THE HEATER 20
9.3 I GNITION ELECTRODE 20
10 EXAMPLES ELECTRICAL INSTALLATION: 20
10.1 T HERMOSTAT CABLE 20
10.2 I NSTALLATION WITH MODULATING ROOM THERMOSTAT 21
10.3 I NSTALLATION OF MORE HEATERS ON ONE THERMOSTAT 21
11 ELECTRICAL DIAGRAM 23
12 EXPLODED VIEWS AND SPARE PARTS 24
12.1 S PARE PARTS 24
12.2 E XPLODED VIEW XR10-30 24
12.3 E XPLODED VIEW XR40-60 25

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 3/25
2Genera
2.1 Safety warnings
The installation and maintenance of this air heater should be performed by an authorized
qualified competent installer in accordance with this manual, using calibrated equipment.
This heater must be installed in accordance with the manufacturer's instruction and local codes.
The qualified installer needs to follow the local health and safety codes.
This appliance may only be operated and serviced by sufficient instructed people. Failing to
follow the instructions can lead to damage to the appliance or the installation.
This appliance can be used by children aged from 8 years and above and persons with reduced
physical, sensory or mental capabilities or lack of experience and knowledge if they have been
given supervision or instruction concerning use of the appliance in a safe way and understand
the hazards involved. Children shall not play with the appliance. Cleaning and user
maintenance shall not be made by children without supervision.
Always follow these safety instructions:
•Make sure that the area around the appliance is dry when working on the appliance.
•Always close the doors and inspection hatches unless adjusting and checking the heater.
Before working on an already installed heater:
- Set the thermostat to lowest setting.
- Close the main gas switch. The main gas switch should be situated upstream in the gas
line near the heater.
- Turn off all electric power to the appliance
After working on the heater always check for gas leaks.
Close the doors and hatches of the appliance.
2.2 Important checks before installation
2.2.1 Pre-check instructions
Before unpacking and installation, please check (i.e. on the data badge) if the heater is in
accordance with the order and if it is suitable for the local present provisions (gas type, gas
pressure, electrical supply etc.)
The heater has been tested in detail on safety and correct operating settings before leaving the
factory. It has been adjusted for the type of gas that is stated on the data badge. Should there
be any doubt, please contact your supplier.
2.2.2 Gas type
The unit is suited for OR Natural gas OR Propane gas. On the labels on the packaging and the
heater can the gas type that the heaters is set up for can be found. In case the heater needs to
be converted to another gas type contact your supplier. It can only be converted by the
manufacturer or its representative.
2.2.3 Standards
The Installation must comply with all applicable local and national standards.
The installation of the air heater must be in accordance with the relevant requirements of the
Gas Safety regulations (for example in GB; The Institute of Gas Engineers IGE UP-1 and 2),
building regulations and the IIE regulations also incorporating the gas safety (installation and
use) regulations. Other national and/or local regulations may apply (the Local Authority ,Fire
Officer and Insurers)

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 4/25
2.2.4 Protection from water and dust
The heater is not waterproof. This means that it may not be exposed to rain, spry or dripping
water. The IP classification is IP00B
The appliance is not designed for use in a very dusty environment. Dust may accumulate in the
heater and may cause a defect of the heater. This is also the case for the room-thermostat.
2.2.5 Protection against dust
The appliance is not designed for use in a very dusty environment. Dust may accumulate in the
heater and may cause a defect of the heater. This is also the case for the room-thermostat
2.2.6 Temperature
Do not install the heater in places where the temperature can rise above 35°C. At higher
temperatures the internal components will degrade much faster. This is not covered by the
guaranty.
2.2.7 Corrosive environment
The heater should not be installed in areas containing any corrosive or explosive vapours. It
should be prevented that chlorine or other corrosive containing vapours are sucked into the air
intake. These vapours will result in corrosion of the heat exchanger and a leakage of
condensate and flue gas. Defects caused by this are not covered by guaranty. Please consult
your supplier. This is also the case for the room-thermostat
2.2.8 Installation distances
Keep sufficient distance between the heater and any obstruction , in connection with safety and
access for service and maintenance. Pay particular attention to any flammable materials.
Please take into account the possibility to open the door of the heater for the necessary service
and maintenance work . Make sure the air flow to and from the heater is unhindered. Any
obstacles should be a minimum of 5 metres away from the front of the heater. Read the
chapter “Installation” carefully.
2.2.9 Maintenance
For the safe and proper operation of the heater periodical maintenance is necessary. When the
heater is not serviced and cleaned in time, it could lead to damage of the heater or its
surroundings.
2.3 Guarantee
The guarantee becomes void when the air heaters are not installed and serviced in accordance
with this manual.

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 5/25
3Technica detai s:
Type XR 10 20 30 40 50 60
Maximum nominal heat input (Nett) kW 14,0 22,8 32,0 44,0 55,0 66,0
Minimum nominal heat input (Nett) kW 9,0 14,8 20,5 26,4 33,0 39,6
Maximum nominal heat input (Gross) kW 15,6 25,3 35,5 48,9 61,1 73,3
Minimum nominal heat input (Gross) kW 10,0 16,4 22,8 29,3 36,7 44,0
Maximum heat output kW 12,8 20,8 29,2 40,2 49,9 60,5
Minimum heat output kW 8,3 13,8 19,1 24,4 30,8 37,0
Efficiency @ max. power (Gross). % 91,4 91,3 91,1 91,4 90,7 91,7
Efficiency @ min. power (Gross). % 91,7 93,0 93,1 92,4 93,3 93,4
Max air output (warm) m3/hr 1.150 2.070 2.600 4.370 5.150 6.300
Throw horizontal (max) m 12 16 23 26 28 30
Throw vertical (max. warm) m 5 5 6 7 7 8
Gas connection G” 1/2” in 1/2” 1/2” in 3/4”out 3/4” out 3/4” out
Electrical Voltage (50Hz) Vac 230 230 230 230 230 230
Electrical Power max. kW 0,250 0,250 0,250 0,450 0,450 0,600
Electrical Power min. kW 0,250 0,250 0,250 0,450 0,450 0,600
Electrical Power stand by. kW 0,004 0,004 0,004 0,004 0,004 0,004
Electrical Current max. A 1,1 1,1 1,1 2,0 2,0 2,6
Emission efficiency, (ηs,flow) % 96,1 93,3 90,6 91,7 91,2 90,8
Seas. space heating efficiency % 76,3 74,8 72,8 73,8 74,1 73,7
NOx emission (GCV) mg/kWh 37 36 35 43 41 42
NOX class 5 5 5 5 5 5
Flue amount max. kg/hr 21,7 35,5 51,3 70,6 88,2 105.8
Thermostat comm.bus system (low volt.) Yes Yes Yes Yes Yes Yes
Sound level (average @ 4 meter) dBA 42 45 45 46 47 49
Min. suspension height horizontal throw m 1,7 1,7 1,7 1,7 1,7 1,7
Flue length max. m 9 9 9 9 9 9
Weight m 36 37 38 78 80 82
Natural
ga
s G2
0
,
heater version
3.3
Nominal supply pressure G20 mbar. 20
Supply pressure (min-max) G20 mbar. 17-30
Gas category I2H
Class B23, C13, C33
Max gas consumption G20 m3/hr 1,5 2,4 3,4 4,7 5,8 7,0
CO2 High G20 % 9,0 9,0 9,0 9,0 9,0 8,9
CO2 Low G20 % 8.5 8,5 8,5 8,5 8,5 8,5
Propa
n
e
, G31,
heater version
3.4
Nominal supply pressure G31 mbar. 30-50
Supply pressure (min-max) G31 mbar. 25-50
Gas category I3P
Class B23, C13, C33
Max gas consumption G31 kg/hr 1,1 1,8 2,5 3,5 4,4 5,3
CO2 High G31 % 10,7 10,7 10,7 10,7 10,7 10,5
CO2 Low G31 % 10,0 10,0 10,0 10,0 10,0 10,0

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 6/25

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 7/25
4Insta ation
4.1 Positioning
•Check that the support is solid enough.
•The heater is designed as free hanging. The heater
should be able to blow the warm air free from any ducting
or obstacles. Also the air intake should be free.
•Keep sufficient distance between the heater and any
obstruction , in connection with safety and access for
service and maintenance. See the drawings in this
chapter. Pay particular attention to any flammable
materials. Please take into account the possibility to
open the door of the heater for the necessary service
and maintenance work . Make sure the air flow to and
from the heater is unhindered. Any obstacles should be
a minimum of 5 metres away from the front of the
heater.
•The heater can be installed horizontally or on an angle
of maximum 45 degrees downwards.
•When the heater is installed other than horizontal,
Always re-adjust the CO2 setting from the gas valve.
•The heaters type 10 and 20 are provided with 2 off
M10 threaded sockets as fixing points (see the
dimension diagram).
•The types 30 and 40 have in the middle a M10 socket and also 4 sockets on the top corners
of the heater
•The types 50 and 60 have on the top and bottom 4 M10 sockets. (see drawings)
•Use preferably the Winterwarm suspension kits.
•Make sure that after fitting, there is no mechanical tension on any connecting gas or electric
supplies.
•If the heater is installed with the air stream vertical downwards the maximum suspension
height is 8 meters. Otherwise the warm air will not reach the floor.
Attention:
See the application-restrictions in this manual (Chapter 2) for further installation restrictions.
min 250
10 t/m 30 min. 500 mm
40 t/m 60 min 660 mm

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 8/25
Available suspensions:
Standard bracket Design bracket
Horizontal or vertical horizontal/vertical rotatable
XR10-30: GA.8610 XR10-30: GA.8630
XR40-60: GA.8620
Suspension kit: vertical Suspension adapter XR10-30
GA.8645 for M10 threaded bar
GA.8690

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 9/25
4.2 Gas connection
The gas supply line has to meet the national valid requirements and possibly the local
requirements of the building inspector, police or fire brigade. (In GB it must comply with Gas
Engineers publication UP-1 and UP-2 together with BS 6891.
A manual isolation valve in the supply line must be placed within reach of the heater, and all gas
lines must be mounted without any mechanical tension.
When testing the supply lines with pressures above 60 mbar, this manual valve at the heater
must be closed.
The working and standing supply pressure must be a minimum of 17 mbar, and a maximum of
30 mbar ,measured at the inlet pressure nipple of the gas control in the heater
In case the heater needs to be converted to another gas type contact your supplier. It can only
be converted by the manufacturer or its representative.
4.3 Electrical connection
4.3.1 230Vac supply
The installation must comply with local and
national requirements, ( as well as IEE
regulations)
Never use a room thermostat to interrupt the
electrical supply to the heater!
Make provisions to completely isolate the heater for maintenance purposes. This can be an
isolation switch (min.3mm contact opening gap) , a power plug or a non-switched fuse spur.
The wiring diagram for the heater can be found towards the end this manual.
The supply is 230Vac. with earth. The control circuit is a two wire low voltage bus
communication.
4.3.2 Room thermostat
The heater can only be controlled by special modulating Winterwarm room thermostats:
The Multi Therm Comfort; modulating digital clock thermostat with optimiser. It can control 1 to
8 air heaters HR10 up to HR60 or 1 to 4 air heaters HR80 up to 120.
The Multi Therm Standard; modulating digital thermostat. It can control 1 to 8 air heaters
HR10 up to HR60 or 1 to 4 air heaters HR80 up to 120.
The Interface printboard; special designed interface module for connecting the air heaters with
Building Mangagement Systems. (0-10V (modulating input) signal, high/low signal,
external reset and other different in and outputs.
ON/OFF thermostat
The heater cannot be controlled with a simple on/off thermostat.
In all cases the communication between heater and thermostat is based on a two wire, low-
voltage connection. In the appliance the wire for the thermostat has to be connected to
connection 4 and 5 (see also electrical wiring diagram) Attention: This also needs a change in
the settings on the print board.
4.3.3 Thermostat installation
When mounting the thermostat, take attention to the following items:
•Mount the thermostat in a place where the air can circulate free pass the thermostat. Take
notice that the sun does not shine directly upon the thermostat (in the winter). Do not
place the thermostat on a cold wall. Place the thermostat on an inner wall free from
draught.
•Never place the thermostat within the throw of the heater.
•Never mount the thermostat near aerials of internal communication networks. These emit
radiation that could lead to disturbance of the thermostat. Always keep some meters
distance.

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 10/25
•In all cases the communication between the heater and the thermostat is based on a two
wire, low-voltage connection. In the appliance the wire for the thermostat has to be
connected to connection 4 and 5 (see also electrical wiring diagram).
Cable specification: signal cable, 1x2x0,8 (shielded and twisted)
Maximum length 250m.
If the cable is chosen too thin, the signal will become too poor. If the cable is not shielded and
twisted the signal might become disturbed in an EMC unfriendly environment.
Keep the thermostat cable separated from mains cables. Connect the earth shield of the cable
only to the earth terminal in the heater.
If these guidelines are not followed it may result in malfunction of the installation or worse, it
could damage the thermostat or the electronics in the heater.
4.3.4 Fuse
On the heater control board there is 1 fuse. See electrical wiring diagram.
F1 and in the power supply of the heater. Replace the fuse only by a fuse of the same type, 5AT
4.4 Air intake / combustion products discharge
Check for compliance with local / national regulations.
Only the described flue material may be used. This goes for the roof or wall terminal and also
for the piping between the heater and the terminal. Only so the installation is approved.
Do not use terminals for condensing appliances. This can lead to water inside the flue system.
In some cases the roof terminal has to be at least 0,5m above roof level (depending on local
regulations).
Pay attention on fresh air ventilation openings on the building. There are local distance
restrictions on placing a flue terminal near the ventilation openings.
4.4.1 Flue material
It is only allowed to use CE marked flue material from the manufacturer Muelink & Grol (M&G)
and Burgerhout, type Alu-fix temperature class minimum T250. These Flue systems can be
bought at your supplier.
Only use one flue pipes from the same diameter as the flue spigots on the heater.
Different manufacturers have different connections systems from the flue pipes. It is not allowed
to combine systems from different manufacturers.
4.4.2 Maximum flue length
The maximum pressure drop in either the air supply pipe, or the flue pipe ,must not exceed 9
metres straight pipe , excluding the terminal. Whenever bends are used the pressure drop is
greater and therefore a 90°bend will count as 2 metres and a 45°bend as 1 metre. All flue
pipes must be of the same diameter as the flue spigots on the heater, and all flue joints must be
sealed. For further information regarding the flue system please contact your reseller.

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 11/25
4.4.3 Flue terminals
The following flue terminals are allowed:
Vertical discharge Horizontal discharge
XR10-30: DDV 80/125 art.no. IA8202 CT 80/125 art.no. IA8113
for h>0,5m above roof IA8218 2-pipe wall terminal art.no. IA8212 or GA8201
XR40-60: DDV100/150 art.no. IA.8101 CT100/150 art.no. IA8112
for h>0,5m above roof IA8107
4.4.4 Condensation in the discharge
system
During heating up, it is possible that condensation is formed in the discharge system. This
however, will evaporate if the heater is operating for a longer period of time.
If the straight length of the discharge flue is longer than 4 meters this condensation will not
evaporate again and accumulate in the heater! Isolation of the discharge pipes or a
condensation trap just at the heater is then absolutely necessary.
6
7
T-piece (6) condensate trap (7) condensate drain
Ø80 art.: IA8223 IA8225 IA8286
Ø100 art.: IA8176 IA8188 IA8288
The maximum flue length not isolated is 4 meters. (do not count bends)
The maximum flue length isolated is 9 meters. (do count bends)
4.5 Installation Roof or Wall terminal
Algemeen
•Check the components on possible damages.
•Combine only with components from same materials and manufacturer.

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 12/25
•Install after national regulation.
•Outside can be cleaned with a wet towel or with some detergent.
Installation Roof terminal
1. Check the components on possible damages.
2. Taking the roofing into account, determine the type of weather collar synthetic file or universal
pitched roof flashing; for a flat roof an aluminium flat roof flashing.
3. Determine where the flue terminal will be positioned.
4. Make a hole for the flue terminal from the outside. Ensure that no
saw dust or dust gets into the appliance.
5. Fit the weather collar..
6. Carefully insert the flue terminal through from the
outside. Attention: do not tum the cap.
7. Put the flue terminal into a vertical position using an
air level. (If desired, cover plates, to be supplied
separately,can be fitted)
8. Fix the supplied wall clamp round the flue terminal and fit it to the roof construction. Do not tighten
the clamp yet.
9. Fit the gasket and the twin-tube connection. Make sure that the gasket is not damaged. Ensure
that the flue tube and the air inlet tube are not exchanged; the flue tube is the pipe in the centre of
the flue terminal.
10. Finally, secure the roof wall clamp and check that all steps have been carried out correctly.
Installing Wall terminal
1. Check the components on possible damages.
2. Determine where the flue terminal will be positioned.
3. Make a hole for the flue terminal. Ensure that no saw dust or dust gets into the appliance.
4. Carefully insert the flue terminal the outside. Attention: do not tum the cap.
5. Fix the terminal horizontally using an air level
6. Mark the holes and drill the holes in the outside wall for the fixation of the terminal.
7. Fix the terminal with screws. Eventually seal the fixation with kit.
8. Fix the shield on inner wall.
9. Fit the gasket and the twin-tube connection. Make sure that the gasket is not damaged. Ensure
that the flue tube and the air inlet tube are not exchanged; the flue tube is the pipe in the centre of
the flue terminal.
10. .Check that all steps have been carried out correctly.

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 13/25
4.5.1 Installation from the flue system parts
These basic instructions are for the flue material that go with this heater.
Elements system ALU FIX thick wall
General
•Distance to conbustionable materials around the flue parts minimal 40mm.
•Use the brackets that go with the flue system.
• Different manufacturers have different connections systems from the flue pipes. It is not
allowed to combine systems from different manufacturers
•The female sockets should have an depth of minimal 40 mm.
•Install without mechanical force on the parts.
•Inclination towards the appliance of 3 degrees (50 mm per meter) to allow the condensate to flow
to the heater.
Sealings
•If the flue parts need to be cut, Clean and round the edges. Sharp edges will damage the seal.
•Follow the instructions from the manufacturer when the connections need to be fixed.
•Do not drill or screw in the parts.!
•Do not try to seal with kit, foam or tape.
•Lubricate the connections only with allowed lubricant from the manufacturer. Maximum 1% of
soap or water is allowed.
•ATENTION! Do not use grease, Vaseline or oil
Fixation
•Fix every elbow on or near the socket.
Exception when connecting the appliance: when the flue pipes before and after the elbow
are shorter than 0.25m, then the 2nd element after the elbow needs to be fixed with a
bracket.
•Horizontal and non-vertical flue pipes:
Maximum distance between brackets 1 m.
On tensile joints, (following the manufacturer’s instructions) Maximum distance between
brackets 2 m.
The distance between the brackets should be spread out equally.
•Vertical piping:
Maximum distance between brackets 2 m.
The distance between the brackets should be spread out equally.
•Inside a shaft:
Check the components on possible damages or blockage..
Check that the pipe is under the right inclination.
Mark the flue pipes and fresh air pipes to avoid a mistake.
Check that the pipes extend minimum 50mm when going through a wall or other obstacle.
Fix the last element before entering the shaft. If this is an elbow, also the 2nd element
may be fixed.
•ATENTION, every system needs to have at least 1 bracket. The first bracket needs to be within
the first 0,5m from the appliance..

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 14/25
5Functioning of the unit
5.1 General
The unit can heat as well as ventilate. By using the temperature-sensor on the unit and the one
in the room-thermostat, the temperature-difference between the two in the room is monitored.
Should the difference become higher than a set value, due to the fact that warm air has
accumulated underneath the roof, the system-fan will start and push the warm air down, acting
as a de-stratification fan.
5.2 Burner cycle
The status and burner cycle is showed on the display in the heater
Display
S
t
atus
D
escription
0
Stand
-
by
Standby,
wa
iting for he
at demand
1
Reset
So
ftware reset
3 Pre-check Zero position check pressure switch
4 Pre-purge 30 seconds of pre ventilation from the combustion fan. The
pressure switch is checked.
5
Pre
-
igniti
on
I
gni
tion without opening the gas valve
6 Igniting Ignition (5 sec), gas valve opens
7
Flame check
Check if
the flame is present
8 Burn The heater burns and starts to modulate.
9 Minimum Before the flame stops, the burner will modulate to minimum
power
10
B
urner off
G
as
valve closes,
t
he flame stops
11 Post Purge Burner fan purges with fresh air
Syst
em
fan
c
ools t
he heat exchanger
Minimum burn time 4 minutes!
The heater will always burn minimum 4 minutes, even if the heat demand stops. This to avoid
an unnecessary large amount of start and stops.
The heater will try 2 times to ignite before it stops and gives an error.
5.3 Delta-T-regulation (temperature controlled de-stratification fan)
In case there is no heat demand, the delta-T-regulation will be active.
When the temperature-difference between the sensor on the unit (the NTC) and the sensor in
the thermostat is bigger than the set value (factory setting standard 8°C), the system fan will
start, at a regulated speed, depending on the differential temperature difference. This operation
ensures an even temperature distribution throughout the building, thus acting as a fully
automatic variable de-stratification fan.
Switch of delta-T-regulation
Should this delta-T-regulation not be required, in the Menu Program Settings on the room
thermostat this regulation can be switched off. See user manual of the special Winterwarm
Room thermostat.
5.4 Summer ventilation
It is possible to let the ventilator run on a certain speed in the summer. Please follow the
instructions in the manual from the thermostat.

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 15/25
5.5 High limit protection
5.5.1 T max. Heat exchanger
The unit contains 2 temperature protections. The NTC thermostat monitors the air temperature
electronically. Should the temperature, as a first step, become too high, the burner will modulate
to the minimum input and the system fan will modulate to the maximum speed.
When the temperature still increases, the burner will switch off. The display will show E05 / E36.
When the heat exchanger has been cooled to normal levels the burner will start automatically.
Should the temperature increase to an unacceptable level, the heater stops. The display will
show L31. Only after a manual reset the heater can start again. Manual reset can be done on
the electronic circuit board or with the special Winterwarm Room thermostat
5.6 Flue Transport Supervision
The unit is provided with a pressure switch to control the transport of combustion air through the
heat exchanger. It checks in the pre purge phase if there is sufficient movement of combustion
air through the heat exchanger by measuring the pressure difference over the heat exchanger.
If the pressure difference is too low in the pre purge phase, the fault L14 will occur. This could
mean that combustion air is leaking from the heat exchanger and so the heat exchanger must
be checked on leakage.
6 Putting into operation and adjustment
6.1 General
Prior to packaging, each unit is checked in detail on safety and functioning. It is adjusted to the
right efficiency of combustion. In general, the heater does not need to be adjusted after
installation, only a check of functioning is necessary. Also obtain a flue gas analysis and record
it for later reference.
Use only a calibrated instrument !
The CO2 value can be adjusted if the CO2 reading differs 0,3% from its setting. Do not ever
turn injudiciously the adjusting screws!
Adjustment of the gas control without a supporting flue gas analysis will invalidate the warranty.
Once the unit is installed according this manual, the unit can be put into operation. Make sure
the gas pipe is clean, gastight and free from air.
Switch on the electric supply with the maintenance-switch, and open the door in order to be able
to observe the first start-up and so become familiar with the functioning of the heater.
Should the gas line not be purged correctly the heater will attempt to start twice before going
into a lock-out condition. Manual reset is necessary in that case.
Do not forget to instruct the end user about a safe use of the heater (presence of gas, place of
the manual gas valve !), the operation of the heater (lock-out indication and reset) and about the
necessary maintenance. This manual must be left with the end user.
6.2 Start by using the thermostat
Put the thermostat in the highest position. The start sequence is always the same
NOTE:The heater will always burn for minimum 4 minutes before it switches off.

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 16/25
6.3 Start through the display in the heater
The manual test mode trough the display in the heater will only work for maximum 10 minutes.
1.Pres and hold the Return and – button for a few seconds. The display will show Lo / St
intermediate.
2.The heater will start up in Low fire.
3.Toggle between Low and High fire by pressing the + and – button,
4.Exit the service menu by pressing the – button until 0 is displayed.
5.The heater will always cool down the heat exchanger for a few minutes.
6.After 10 minutes the test mode will automatically end.
Adjusting the gas-control
In principle, it is not necessary to adjust the gas control after putting the unit into operation.
In case it needs to be adjusted, (e.g. after
fitting a new one), this must be done only by
a qualified person. Only use calibrated
instruments ! A poor adjustment can lead
to overheating and / or production of the
poisonous carbon monoxide !.
There are two screws to adjust the gas
control, the Offset adjuster and the Ratio
adjuster.
The Offset adjuster is used in Low fire. The Ratio adjuster is used in High fire.
Put the heater into operation at high fire through the display in the heater, Mode 4.
If the heater does not ignite while sparking, you can, if necessary, close the air-openings of the
coloured ring on the gas-air mixer with thumb and forefinger during ignition. The mixture will
become richer and will ignite more easily.
Look for the correct CO
2
values in the table with technical data.
Readjust the CO
2
when the deviation is more then 0,3%
1 Check the CO
2
in High fire (mode 4)
Decrease CO
2
turn the Ratio adjuster to the right (less gas).
Increase the CO
2
turn the Ratio adjuster to the left (more gas).
2 Then check the CO
2
in Low fire. (mode 2) The CO
2
in low fire is lower than the high fire
CO
2
.
Decrease the CO
2
turn the Offset adjuster to the left.
Increase the CO
2
turn the Offset adjuster to the right
After adjusting the CO
2
in Low fire, return to high fire, and Readjust the CO
2
with the Ratio
adjuster.
Then return to Low fire again and eventually readjust the CO
2
with the Offset adjuster.
Offset adj.
Ratio adj.
P out
P offset
P in

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 17/25
Repeat these steps until both values are OK.
Never forget to check the CO (carbon monoxide ) production of the heater!!! Too much CO
means mostly that the mixture is too rich. CO value should always be below 100 ppm.
7 Prob em so ving
7.1 General
When it turns out that the problem is not caused by the external circumstances (i.e. no electric
supply power or no gas), please take the following instructions into account. Please remember
the built in waiting times of the heater (do not react too soon!) and the signals of the LEDs and
the code on the display on the electronic circuit board.
Volatile lock out Can only be reset by hand
Display Explanation Cause
L-0 Internal
error
Internal error 13
L-1 Ignition error After ignition only 5 seconds flame 1
No flame 2
L-2
L-3
Internal
error
Internal error 13
L
-
4
E
-
error lon
ger than 24
hr
12
L-5 Burner fan Burner fan does not work. 6
L-6
L
-
7
Burner fan Burner fan rotates at the wrong speed. 7
L- 8, 9,
10, 11,
12
Internal
error
Internal error 13
L-13 Pressure
swi
tch
Pressure switch is closed in stand by 14
L-14 Pressure
switch
Pressure switch does not close at pre-purge 11
L
-
15
Over
heat
Sensor
he
at exchanger is overheated
3
L-16 Flue temp. Flue sensor is overheated 3
L-17, 18,
19
Internal
error
Internal error 13
L
-
20
Flame err
or
Flame detected after
closi
ng
g
as valve
15
L-21 Flame error Flame detected before opening gas valve 16
L
-
20
Flame error
Flame failure during burning
detected
5
L-25 Sensor error Sensor heat exchanger fault 4
L
-
26
Sensor
error
Fl
ue s
ens
or f
ault
4
L-27, 28,
29, 30,
31
Internal
error
Internal error 13
L
-
32
Sensor
error
Sensor
heat excha
n
ge
r f
ault
4
L-33, 34,
35, 36,
37, 38
Internal
error
Internal error 13
L-39 Pressure
switch
System fan switch not in OPEN position 14
L-40 Pressure
switch
System fan switch does not close during pre-purge 11
L-41 Pressure
switch
System fan switch not closed during post circulation 11
L-42 Flue
temperature.
Too many errors on hot flue temperatures 3

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 18/25
L
-
43
Overh
eat
Too many errors on
heat
ho
t
exchanger temperature
s
3
Temperately errors, the will disappear when the cause is taken away
Display Explanation Cause
E00, to
04
Internal
error
Internal error 13
E
-
05
Over
heat
Overheat heat exchan
ger sen
sor
3
E-06 to
13
Internal
error
Internal error 13
E-14 Flame error Flame detection when that should not be 16
E-15 to
22
Internal
error
Internal error 13
E-23, 24 Flue sensor Flue sensor not detected
E
-
30
-
31
Flue sensor
Flue sensor
short
circuit
E-34 Reset
button
Too many reset actions in a short time 9
E
-
36
Over
heat
Overheat heat exchan
ger
sensor
3
E-38, 39 Heat
exchanger
sensor
Sensor heat exchanger not detected 4
E-48, 48 Heat
exchanger
sensor
Heat exchanger sensor short circuit 4
E-65 Supply
voltage
Supply voltage too low
E-66 Supply
voltage
Supply voltage too hot
E-67 Pressure
switch
Too many pressure switch errors 11
E-68 Flue temp
sensore
Flue temperature too high 3
E
-
69
int
ern
al
A
ppliance
temporarily
paused, automatic r
estart will
follow
13
Warnings
Display Explanation Oorzaak
A-00,
t/m 06
Internal error Internal error 13
A-07 Heat
exchanger hot
Heat exchanger hot, heater will reduce power
automatically
3
A-08 Flue sensor
too hot.
Flue gas hot, heater will reduce power automatically 3
A
-
09
Gas
pressure
G
as
pressure
switch open
(whe
n mounted)
17
Case 1: Within 5 sec flame, then flame failure.
•The flame is not detected. Check the ignition cable and electrode. (cable resistance 1k
Ohm).
•The electrical earth of the heater is poor,
•The print board is defective.
Case 2:
•There is not enough gas pressure.
•The mixture of gas/air is poor, adjust the gas valve
•The gas valve does not open, check during ignition for 230V on the valve.
•Check whether the ignition electrode sparks, replace cable, electrode
Case 3: Heat exchanger too hot
•Check whether the system fan blows enough air.
•Check the setting of the gas valve, the heater may me overloaded.

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 19/25
Case 4: Temperature sensor on heat exchanger error.
•The sensor has internally 2 sensors. These differ too much. Measure the resistance
from each sensor, the resistance should be 20K at 25°en 25K at 20°. If the measured
values differ too much, replace sensor.
•L-25 is heat exchanger sensor, L-26 is flue sensor
Case 5: Too many flame failures while burning
•The setting of the gas valve is not ok, adjust the gas valve
•The flue outlet is blocked
Case 6: The premix does not run
•Premix fan is Blocked or the wiring is bad
•Premix fan is defective
Case 7: The pre-mix fan runs, but not the correct speed.
•Check if the fan runs smoothly.
•Check the wiring.
Case 9: Reset button error
•Too many switches on reset button in a short period of time. These error will disappear
after some time, or if the main power is disconnected for a while.
Case 10: Safety relay error
•Plug J2 is not connected well, the bridge on connector J2 between 1 and 4 is not
connected well.
•Otherwise change print board.
Case 11: Insufficient air transport over the heat exchanger
•Check the pressure switch and the connections
•Check the heat exchanger for flue leakage
Case 12: E-fault is 24 hours present.
•An E fault should disappear after a while. When this error is present longer than 24 hr,
something is wrong. Check the error code after a new power up.
Case 13: Internal error.
•Power up the heater again, else replace the print board.
Case 14: Pressure switch closed during stand by.
•When the heater is in standby, the pressure switch should be in the rest position. When
it is in the closed position the contact could be stick, or water could be in the small
hose.
•Replace the switch or dry the hose.
Case 15: Flame detected after closing of the gas valve.
•The gas valve closes too slow, replace the gas valve
•The ionisation electrode is wet. Dry or clean the electrode. Or change the electrode.
Case 16: Flame detected before opening the gas valve.
•Check it there is really a flame before ignition, if that is the case, replace the gas valve
•The ionisation electrode is wet. Dry or clean the electrode. Or change the electrode.
Case 17: Gas pressure switch open.
•Check if the gas supply valve is open
•Check the standing gas pressure.
•Check while running the appliance that the gas pressure is sufficient.
Heater does start, but shows other problems:
Heater ignites explosively, has often flame failures:
•Check the right setting of the gas control, the right CO
2
setting is important for the
correct ignition.
•Check the ignition cable (1kOhm )
•Check the setting of the ignition electrode, the spark has to be formed between the
electrodes and not between the electrode and the burner.
Insufficient output
•The heat output of the heater will be insufficient if there is too much resistance in the
inlet- or outlet flue system. In this case the premix-burner-fan will be on full speed, but

Instructions condensing Air heaters type XR version XR-GB-4001-a Page 20/25
because of the high resistance too little air is moved and therefore also too little gas.
The pressure in the outlet flue for example, will normally never be above 30 Pascal.
Non modulating system fan
•System fan (M1) does not start or does not vary in speed; Check first the functioning of
this fan by connecting it to 230 Volts. Check with a multi-meter if the different lower
tensions are secondary present on the transformer as well. The fuse could have failed.
If the motor and transformer are OK, the cause of the problem must be in the heater
control, as the heater control dictates the different voltages from the transformer to the
fan-motor. In that case, replace the heater control.
8 Maintenance / spare parts
The heater must be inspected and cleaned regularly (once a year) by a qualified installer who
understands this appliance.
This is all the more important as the circumstances are heavier, especially in case of dust,
humidity, high frequency of switching on/off etc.
Activities:
8.1 General inspection
•Check the overall condition of the installation. Check the heater, the thermostat, the wires
and the gas line.
•Clean and inspect the condensate pipes and the siphon every year. Always fill the siphon
after cleaning with water to prevent flue gas escaping in the room.
8.2 Inspection of the heater
Before starting the inspection, switch off the electric power to the heater with the maintenance-
switch and close the manual gas valve.
•Take out the burner, complete with flange and pre-mix fan, by unscrewing the 6 off M6
socket screws and you have taken off the ignition and fan wires
•Check the heat exchanger from the inside for dirt and/or damage.
•Check the burner on damage and clean the ignition electrode if necessary . CAUTION: do
not twist the electrode out of shape!
•Check the air supply and the flue discharge.
•Clean eventual the inside of the heater with a vacuum cleaner.
•In case the heat exchanger is dirty on the outside, clean it with a soft brush. Never use a
steel wire brush!
•Clean the fan-grid with a vacuum cleaner and a brush.
•Put the burner back in (renew the gasket)
After this, check the heater on efficiency of combustion and adjust these if necessary
Check the heater operates correctly.
8.3 Ignition electrode
For the correct ignition of the burner it is important that the ignition
electrode is adjusted right.
•The distance between the electrode and the burner should be
5.0 ±0.5 mm.
•The distance between the two electrodes should be 3.6 ±0.4
mm.
•Check the setting of the ignition electrode, the spark has to be
formed between the electrodes and not between the electrode and the burner.
9Examp es e ectrica insta ation:
9.1 Thermostat cable
In all cases the communication between the heater and the thermostat is based on a two wire,
low-voltage connection. In the appliance the wire for the thermostat has to be connected to
connection 4 and 5 (see also electrical wiring diagram).
5 ±0,5
3.6±0,4