STERLING
Room Sealed Fanned Balanced Flue
Combination Boiler
GAS SAFETY ~INSTALLATION AND USE) REGULATIONS.
It is the law that all gas appliances are installed by a competant person
in accordance with the above regulations
(For use on natural gas only. G20)
G.C. No 47 980 04
from serial number . . . . . . . . . . . .
FF
Installation and
Senrkhg Instructions
(leave these instructions with the user)
Looking Good.Heatfng Better
Page No.
Health and Safety Information
1. INTRODUCTION
1.
1.1.
1.2.
1.3.
1.4.
1.4.1.
1.4.2.
1.4.3.
1.4.4.
1.5.
1.6.
1.6.1.
1.6.2.
1.6.3.
1.6.4.
1.6.5.
1.6.6.
1.6.7.
General Description, Special Features, Guarantee
Dimensions Fig. 1
Technical Data
Ckarances
Wall Thickness
Rear Flue Outlet Fig. 2
Side Flue Outlet Fig. 3, Fig. 3a, Fig. 3b
Other Flue Arrangements, Horizontal Fig. 3c
Vertical Flue Arrangements, Fig. 3d, Fig. 3e, Fig. 3f Fig. 3g
Description of Components and Location Fig. 4
Description of Operation
Central Heating Fig. 5
Hot Water Fig. 6
Gas (also see 2.7)
Functional Flow Diagram Fig. 7
Safety Controls
Functional Flow Wiring Diagram Fig. 8
Illustrated Wiring Diagram Fig. 9
1
2
2
3
3
3
4
4
4
5
6
7
7
7
8
8
8
9
10
2. INSTALLATION REQUIREMENTS
2. 1. General
2.2. Location
2.3.
2.4. Siting the Flue Terminal Fig.
2.5. Air Supply
2.6. Electrical Supply
2.7. Gas Supply
3. SYSTEM
3.1.
3.2
3.3.
3.4.
3.5.
3.6.
3.7.
3.8.
3.9.
3.9.1.
3.9.2.
3.10
3.11
3.12
3.13
3.14
Water Circulation System
GUIDANCE
General
System Controls
Pump Fig. 11
Expansion Vessel
Mains Water Connection
Filling and Recharging
Make up System
Pipework
Domestic Expansion Vessel
Boiler Replacement
Existing Systems
Cylinder
Inhibitors and Water Conditioners
Add on Devices
Heating and Hot Water Systems Fig. 14, Fig. 15,
Shower Application Fig. 17a
Fig. 12, Fig. 13 (page
10
12)
Fig. 16,
Fig. 17
11
11
11
11
12
12
12
12
13
13
13
13
13
13
13
13
14
14
14
14
14
15
16
(4
4. INSTALLING THE BOILER
CONTENTS (cant)
No. Page
General Information
4.1.
4.2.
4.3.
4.4
4.5.
4.6.
47
4.8.
4.9.
4.10.
4.11.
4.12
4.13.
4.14.
Positioning the Boiler Fig. 18
Rear Outlet Flue Fig. 19
Side Outlet Flue Fig. 20
Jig Plate Fig. 21
Gas and Water Connections Fig. 22
Water Connections
Gas Connection
Fitting the Boiler Fig. 23
Fitting the Safety Valve Fig. 24
Fitting the Flue (up to 700 mm long) Fig. 25
Fitting the Flue (over 700 mm long)
Connection the Pressure Switch Fig. 26
Electrical Connections Fig. 27
Vertical Flue Figs. 28.28a, & Fig. 29
5. EXTERNAL CONTROLS
5.1. Programming and Zone Valves
5.2. Honeywell & Satchwell Controlled Zones Fig. 31
5.3. Frost thermostat Fig. 32
5.4. Room Thermostat Fig. 32a
17
17
17
18
18
18
18
18
19
19
19
20
20
20
21
Fig. 30 22
22
22
22
6. COMMISSIONING
6.1.
6.2.
6.3.
6.4.
6.5.
6.6.
6.7.
6.8.
6.9.
6.10.
6.11.
Hot Water Circuits. Filling Fig. 33
Central Heating Circuits, Filling, Fig. 34 G
Lighting the Boiler Fig. 35
Gas Rate Adjustment Fig. 36,37 & Fig. 38
Domestic Hot Water, Flow Rate Adjustment (see also 6.7, Fig. 393)
Adjusting the Heating System By-Pass Fig. 39
Domestic Hot Water. flow Rate Adjustment Fig. 39a
Pump Switching Adjustment Fig. 39b
Central Heating Temperature Differential Setting Adjustment Fig. 39c
Fitting the Casing Fig. 40
Time Clock Operating Instructions
7. ROUTINE SERVICING
General Requirements
7.1.
7.2
7.3
7.4.
7.5.
7.6.
7.7.
To Remove Front Casing Fig.41
To Remove Combustion Chamber Fig.42
To Remove Burner Assembly Fig.43
To Remove Pilot Fig.44
To Clean Heating Return Filter Fig.45
Cleaning and Replacement of Parts
To Check Operation of Safety Valve Fig.46
23
23
23
24
25
25
25
25
26
26
27 & 28
29
29
30
30
30
30
30
30
(ii)
8. REPLACEMENT OF PARTS
iZQNWXG (con0
Page No,
8.1. To Replace Electrodes Fig. 46
8.2.
8.3. To Replace Safety Overheat Thermostat 105°C Fig. 47
8.4.
8.5.
8.6.
8.7.
8.8.
8.9.
8.10. To Replace Pump Head Fig. 55
8.11.
8.12.
8.13. To Replace Air Separator Fig. 59
8.14.
8.15. To Replace Boiler Limit Thermostat Fig. 61
8.16.
8.17. To Replace High Tension Transformer Fig.63
8.18.
8.19. To Replace Solenoids Valves Fig. 66
8.20.
8.21. To Replace Fan Assembly Fig. 68
8.22. To Replace Pressure Switch (Horizontal Flue) Fig. 69
8.23.
8.24. To Re-pressurise Expansion Vessel Fig. 70 .
8.25. To Replace Pressure Gauge Fig. 7 1
8.26.
8.27.
8.28.
8.29.
8.30.
8.31.
8.32. To Replace the Thermometer Fig. 78
8.33.
8.34. To Replace Safety Valve Fig. 80
To Replace Probe Fig. 46a
To Replace Overheat Thermostat 110°C Fig. 48
To Replace Change Over Valve Microswitch Fig. 49
To Replace the Flow Switch Assembly Fig. 50
To Replace Venturi Fig. 5 1
To Replace Primary Heat Exchanger Fig. 52
To Remove Electrical Control Box Fig. 53, Fig. 54
To Replace Change Over Valve Fig. 56 & Fig. 57
To Replace Secondary Heat Exchanger Fig. 58
To Replace Thermistor Fig. 60
To Replace D.H.W. Thermostat Fig. 62
To replace Printed Circuit Board Fig. 64, Electrical box layout Fig. 65
To Replace Heating Body Linings Fig. 67
To Replace Pressure Switch (Vertical Flue) Fig. 69a
To Replace the Domestic Expansion Vessel Fig. 72
To Replace Main Burner Fig. 73
To Replace Burner Manifold Assembly Fig. 74
To Replace Expansion Vessel Fig. 75
To Replace Viewing Window Fig. 76
To Replace Main Gas Valve Body Fig. 77
To Replace the Time Clock Fig. 79
31
31
31
31
32
32
32
33
33
34
34
34
35
35
36
36
38
37
38
38
38
39
39
39
39
40
40
40
41
41
42
42
42
43
9. FAULT FINDING
9.1.
9.2.
9.3. Domestic Hot Water Operation
9.4. Fault Finding Tabular Chart
SHORT SPARE PARTS LIST
Logic Sequence
Central Heating Operation
44
45
46
47
Rear cover
(iii)
CONTROL OF SUBSTANC-RMFUJ, TO w
To comply with the Control of Substances Harmful to Health Regulation 1988 we are required to
provide information on the following substance that is contained in this appliance.
Descriution
platerial
Precautionq
Combustion Chamber Lining
Alumino Silicone Fibre
During servicing, keep the dust generation to a minimum and avoid
inhaling any dust and contact with the skin and eyes. Normal handling
and use will not present any discomfort, although some people with a
history of skin complaints may be susceptible to irritation.
When disposing of the lining ensure that it is securely wrapped and
wash hands after contact.
The STERLING FF is a wall mounted, low water content
fanned balanced flue appliance suitable for central heating
and hot water via a non storage water to water heat
exchanger. The maximum output is 23 kW (78480 Btuih).
The boiler is designed for sealed systems only and included
in the appliance are the expansion vessel, circulating pump,
temperature and pressure gauges, safety valve, electric
connection box, domestic expansion vessel and time clock.
1) The standard flue assembly supplied with the boiler is
100 mm (4 in) dia pipe, can be directed to the rear or to
the lef or right and can be extented to a maximum length
of 3 m, or 1.6 metres horizontally using the available 90”
bend (see sections 1.4.1, 1.4.2 and 1.4.3 figures 2. 3, 3a,
3b, 3~).
2) Vertical flue option (see section 1.4.4.).
Guarantee
The manufacturer’s guarantee on this appliance is for 12 months from the date of purchase. The guarantee is void, if the.
appliance is not installed in accordance with the recommendations made herein.
1.1 DIMENSIONS
Special features include :
-Output to central heating fully range rated between
l/3 and full output.
-High efficiency.
-Special jig plate enabling all pipework to be
installed before installiig appliance.
-Independent control over central heating flow
temperature and hot water.
-Fully adjustable central heating flow temperature.
-regulation between 40” C and 82” C.
-High limit thermostat for both boiler and hot water.
-Water flow switch to protect appliance.
-Suitable for showers with compatible mixer valves.
- 7 day programme time clock.
~\_
B
c ’ --
I\
t-1
---
---- -
2%
_--
-1 -2
r-
‘KI
w
I ;
I ’
1 I
+
LI
1 L
.,- -. ,
X-3
-I
--+
I
REAR OUTLEl
/ -f
~
_-
SIDE OUTLET
1
mm
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
820.5
391.0
365.0
100.0
169.5
654.5
43.0
50.0
75.0
260.0
150.0
972.5
13.0
61.0
30.0
152.0
112.0
-7
in
32.3
15.4
14.4
4
61‘1
25.7
1.7
2.0
3.0
10.2
6.0
38.3
0.5
2.4
1.2
6.0
4.4
Fig.1
2
1.2 Technical Data
1.2
1.3
Hot water
Input . .._....................................... 28.90 kW 98612 Btulh
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.00 kW 78480 Btulh
Water flow raised
45 “C (81
Water iIow raised
35 ‘C (63 “F) .............................. 9.5 Vmin
Water flow raised
30 “C (54 “F). ............................. 11.1 Ymin
Maximum temperature.. ............. 60 T
Maximum pressure.. ................... 10 bar
Minimum working pressure.. ...... .6 bar
Gas rate ...................................... 2.743 m3/h
Burner pressure .......................... 11.8 mbar
Central heating
Maximum input.. ........................ 27.64kW 94313 Btti
Maximum output.. ...................... 22.00 kW 75068 Btti
Gas rate (maximum) ................... 2.63 m3/h 92.98 @lh
.lrner pressure.. ........................ 11.2 mbar 4.5 in wg
.,rinimum input
Minimum output.. ....................... 7.64 kW 26062 Btu/h
Gas rate (minimum)
Burner pressure.. ........................ 1.5 mbar 0.6 in wg
Minimum flow rate
Maximum pressure.. ...................
At the maximum pressrrre loss of the fiue
Temperature of the products of
combustion : . . . . . . . . . . . . . . . . . . . . . . . . . 98 T 208 OF
The CO content of the dry free air
products of combustion : . . . . . . . .
Manifold injectors 14 of . . . . . . . . . 1.28 mm 0.05 in
Gas section restrictors 213 valves
"F)
.............................. 7.4 I/min
...........................
................... 1.0 m3/h
..................... 300 lib 1.1 gal/min
l/3 valve.. .... 2.3 mm 0.09 in
security valve ...... no restricior fitted
10.85 kW 37020 Btuih
2.5 bar 36.5 psi
0.0136%
Natural gas
4.4 mm 0.17 in
1.7 ga.I/min
2.1 gaI/min
2.5 gaI/min
140 OF
150 psi
9 psi
96.87 fi3h
4.7 in wg
35.31 ft3/h
Connections
Gas
..............................................................
Heating flow
Heating return..
Mains cold water inlet..
Hot water outlet..
Electrical supply 240 V - 50 Hz, fused at 3A.
Electrical consumption . . . . . . . . . . . . . . . . . .._.............
Internally fused, two at 2A (BS 4265)
Weight . . . . . . . . . . ._.._.._........_....... . . . . . . . . . . . . . . . . . . . 42 kg
Water capacity . . . . . . . . . . . . ._.,. . . . . . . . . . . . . . . . . . . . . . . . . 4 Iitres
Ignition - ANSTOSS continuous spark generator
Ignition electrode - SAPCO
Ignition probe - SAPCO
Thermistor - SIEMENS
Boiler fiiit thermostat - SOPAC /JAEGER (85X)
Hot water limit thermostat - SOPAC /JAEGER (57°C + 3°C)
Safety overheat thermostat (TOKOSWHCH - (105°C)
Overheat high- Iiit thermostat (TOKOSWITCH - (1lO’C)
Gas valve - AEMF
Fan motor - SEL
Pressure switch - DUNGS 88 Pa I 49 Pa
Pump head - GRUNDFOS UP 15/60
I
C.H. expansion vessel initial charge pressure - 0.65 bar (9.6 psi)
Domestic expansion vesseI initii charge pressure .
................................................
............................................
................................
.........................................
(manual reset)
(automatic reset) (ELMWOOD - (105’C)
(ELMWOOD
22 mm copper
22 mm copper
22 mm copper
15 mm copper
15 mm copper
195 watts
92.4 lb
7 pints
2 bar (30 psi)
3
1.4
Minimum clearances around Boiler
Top above air duct . . . . . . . . . 50 mm (2 in)
Bottom below case. . . . . . . . . . 150mm (6in)
. . . . . . . . . . . . . . . . . . . . . . 100mm (4in)
Sides
Front. . . . . . . . . . . . . . . . . . . . . . . . . .
6OOmm(24in)
Wall Thicknesses
The standard fIue assembly can accomodate the folrowing thicknesses.
Rear : from 55 mm to 576 mm
Side : from 55 mm to 392 mm
(this allows for a minimum dearance of 100 mm between the appliance and the side wall. As this dimension
increases, so the maximum side waII thickness available decreases).
Extension flue assemblies are available to accomodate waII thicknesses of:
Rear : from 577 mm to 2876 mm
Side : from 393 mm to 2692 mm
See figs. 2 and 3 for details of number of extensions required.
IMPORTANT NOTE : The extension ducts supplied. up to a maximum of 3, wiII in fact permit a greater length than
indicated to be covered. The ducts MUST be cut so that the maximum length from the centre Iine of the flue turret to
the outermost point of the air duct DOES NOT EXCEED 3 metres horizontal. Greater length must not be used.
See sections 1.4.1. 1.4.2. 1.4.3.
3
Rear Flue Outlet Hobontal
should not exceed 1.6 metres
REAR OUTLET ASSEMBLY
To cut flue assembly to length
- Measure wall thickness (T).
- Add 74 mm, tthis will give required lentgh Q.
- Mark plastic air duct for length (L) and cut off
surplus (from plain end).
N.B. If extension sections are used ensure these are
fiily pushed together, see figs. 3b and 3c and a fall of 5
mm per metre length should be provided (see section
- Cut off same amount from aluminium flue duct
Flue extension accessory
Part No. 62823.00
(G.C. 264459)
(1 metre length)
1.4.2
‘ig. 2
Side Flue Outlet Horizontal
Fig. 3
Fig. 3a
SIDE OUTLET ASSEMBLY
PLASTIC AIR DUCT
internal
To cut ffue assembly to length
- Measure from external wall face to centre line of
STERLING FF and substract 37 mm (this will give
required length “L”).
- Cut
off
surplus i?om plastic air duct (plain end).
N.B. If extension sections are used ensure these are
filly pushed together, see figs. 3b and 3c and a fall of 5
- Cut off same amount from
I
Other Flue Arrangements Hotizontal
Fig. 3c
1. Distance from internal comer 300 mm without
kit,107 mm with kit No 76216 (GC No 264 833).
2. Distance below balconies or eaves 200 mm
without kit, 107 mm with kit No 76216 (GC No
264833).
3. Appliance is normally supplied packed with
standard 650 mm staight flue section. Additional
straight extension lengths of 1 metre, part No
62823 (GC No 264 459), can be use up to a total
straight length of 3 metres. It is also possible to
incorporate one bend in the flue using part No
65572 (GC No 264 835). In this case the length
Ll + 12 should not exceed 1.6 metres
horizontally.
4
1.4.4
Vertical Flue Arrangements
a) Straight ffue (fig. 3 d)
1) Adaptor.
2) Extensions (9.5 m maximum).
3) Roof flashing.
4) Terminal.
6) Reducer.
Fig. 3 d
b) Flue with two 45O bends (fig. 3 e)
1) Boiler adaptor.
2) Extensions (8 m maximum).
3) Roof flashing.
4) Terminal.
5) 45’ bend.
6) Reducer.
Fig. 3 e
--I
Fig. 3 g
5
c) Flue with four 45’ bends (fig. 3 f and 3 g)
1) Adaptor.
2) Extensions (6 m maximum) tig. 3 f and 3 g
including horizontal (2 m maximum) fig. 3 f.
3) Roof tlashiig.
4) Terminal.
5) 45’ bends (x 4 maximum) fig. 3 f and 3 g.
6) Reducer.
With the exception of (3) roof fIashing and (4)
terminal, all other fittings are designed for interd
installation only.
N.B. In these two arrangements tigs. 3 f and 3 g, the
total length of straight extensions m not exceed 6
meters with a maximum of 4 x 45” bends.
Horizontal run & not exceed 2 meters.
1.5 Description of Components and Location
1
2
6
3
35
27
-
10
-
2i 22 20 31 19 23 17 18’25
Fig. 4
The appliance is mounted in a steel case which has a
white epoxy resin paint finish.
1. Chassis:
The chassis is a rigid plated mild steel pressing on which
all components are mounted.
2. Flue hood:
Is an aluminium alloy casting onto which the fan is
mounted.
3. Combustion chamber:
This is assembled from a number of components
mounted onto the chassis. The front panel is simply
removed for servicing complete with the expansion vessel,
a hook is fitted below the appliance to accept and retain
the panel during servicing.
4. Expansion vessel:
The expansion vessel has a capacity of 5.4 litres (1.19 gal)
and is sized for a normal system water content where the
load is equivalent to the maximum output of the boiler.
The charge pressure is 0.65 bar.
5. Flame supenrision device (not illustrated).
6. Multigas burner comprising: stainless steel blades (14)
and a manifold with injectors (14).
7. Gas section including two stage solendid valves and
security solendid valve.
6. Secondary heat exchanger :
The secondary heat exchanger is a plate type heat
exchanger. A thermostat is fitted on the pipework limiting
the domestic hot water temperature to a maximum of 57
f3” c.
9. Change over vaIve :
The valve is activated by a demand for domestic hot
water, closes the heating circuits, and directs water to the
secondary heat exchanger.
fO.EIectriciaI box containing :
Mains connection
Fuses
Printed circuit boards
Connections for external controls
Connections for fan, pressure switch and flow switch
Connections for pump
Connections for change over valve and for gas solenoid
valve
Indicator LEES.
.ll. Solenoid valve :
Block on which 4 valves are mounted :
l/3 valve - 1 st stage valve-heating and hot water (blue)
2/3 valve - full output to hot water (black)
2/3 valve - (variable valve) central heating (orange)
Security valve (grey).
12. Grundfos pump motor
13. Air separator and vent directly connected to the pump
inlet (not illustrated).
14. Regtdation screw to adjust output to heating (2/3
valve).
15. Heating body compristig :
Copper finned tube heat exchanger protected with silicone
resin paint. Combustion chamber in aluminium coated
steel. Combustion chamber lining - ceramic fibre panels.
16. High limit thermostat (manual reset).
17. Water service tap (not illustrated).
18. Flow isolating valve - heating (not illustrated).
19. Gas service tap (not illustrated).
20. Domestic hot water outlet with regulator (not
illustrated).
21. Safety valve with drain tap (not illustrated).
22. Heating return isoIating vaIve with filter (not
illustrated).
23. Indicator LEDS.
24. Thermometer indicating boiler flow temperature.
25. Manual lock out reset.
26. Selector switch - hot water or&/OFF/heating and hot
water.
27. Adjustment to regulate heating tlow temperature.
26. Pressure gauge.
29. Pressure switch (not illustrated).
30. Domestic expansion vessel (not illustrated).
31. Water flow switch (not illustrated).
32. Tiie clock.
33. Fuses.
34. Data badge position.
35. Control thermistor.
6
~6 Descdption of Operation
1.6
The STERLING FF a is combination boiler providing
central heating and hot water. Hot water is provided on
a demand basis. For the duration of the demand for
hot water the central heating is interrupted.
The appliance operates in two modes. A hot water only
setting where it operates only on hot water demand
and a hot water + central heating setting providing
central heating and switching to hot water on demand.
1.6.1 Central Heating
The pump (21) circulates water which returns to the
boiler via the return valve (31) which incorporates a
filter (30) Before reaching the pump it passes through
an air separator and air purger (17). The return water
passes through the heat exchanger (2) where it is
heated. It then passes through the change over valve
(19) which in heating mode is in its rest position and
out via the flow valve (27) to the radiator circuits (34).
An expansion vessel (13) is fitted in the primary circuit.
Temperature control is by means of a temperature
sensing thermistor and potentiometer. These signals
are fed to a comparitor.
When the flow approaches the set temperature, the
variable gas valve is closed and the boiler continues to
fire on l/3 soleno?d valve (11). When the set
temperature is reached, the boiler switches off. If
flow temperature reduces, the l/3 solenoid valve
opens followed by the variable solenoid valve (10).
Temperature adjustment is between a minimum of
40°C approx. and a nominal maximum of 82°C.
The boiler is protected by high limit thermostats (4) and
(see fig.
5)
(38) the operation of which interrupts the electrical supply
to the security solendid valve and extinguishes the burner.
1.6.2 Hot Water
When there is a demand water flows in from the cold
mains supply (26) through the water section part (35) of
the change over valve (19). The inclusion of a venturi (24)
produces high pressure under the diaphragm (23) causing
it to rise. This movement is transmitted to the change over
valve closing the heating port and opening the hot water
port, as shown (20). The primary water heated by the
boiler now passes through the water to water heat
exchanger (18) where it flows through alternate plates
indirectly heating the DHW.
The rising of the change over valve spindle causes :
1. The opening of a microswitch stopping the pump.
This circuit is remade by a second microswitch making
when the hot water port is fully open.
2. The by-passing of the boiler thermistor brings the
boiler under control of a fixed temperature thermostat
(32) which operates on the 23 fmed solenoid (12).
The D.H.W. flow rate is adjustable by a restrictor (25) and
a liiiting thermostat (32) reduces the gas rate when the
domestic hot water reaches 57’C by interrupting the
electrical supply to the hot water solenoid (12).
If the primary circuit reaches 85°C the limit thermostat (16)
closes both solendids valves.
A domestic expansion vessel is fitted in the D.H.W. circuit
(see fig. 6)
(36).
Central Heating
17
I ILL
/I----.-.
3, ----lO.ll-
T
16
11 -111
IL 'I IL- I"
L*-l
‘---q ,*
16
Hot water
1
16
30
31
Fig. 5
27
27
Fig. 6
7
1.6.4
1.6.5
Gas
(see figs. 5 and 6)
When the main gas tap (33) is turned to the on position
gas is admitted to the gas section (7).
When there is a demand for heating or hot water, the
security solenoid valve (9) and the l/3 soleno’id valve
open together, which allows gas to pass to the burner.
Srrnultaneously the hight tension transformer is energised
and produces a stream of sparks from the ignition
electrodes (3) whitch light the main burner.
The flame supervision (5) is controled by ionisation
circuit.
r:
FUNCTIONAL FLOW DIAGRAM
Summer
If the main burner is not established after 5 seconds, the
boiler falls safe to lock out and has to be reset manualy.
There are 4 solenoid valves : the right hand (grey) valve
(9) is the security valve, the blue valve (11) fixed at l/3 of
max rated output, the hot water (black) valve (12) fixed at
2/3 of maximum rated output, the left hand central
heating (orange) valve (10) which is variable up top 2/3
maximum rated output.
The gas admitted by the orange valve is varied by adjuster
(6)
(see section 6.4).
D.H.W.
OFF
High
Limit
-+ Stat + Pump --+ Flow
Water
Switch 2
I i-l
(manual reset)
I
Fan ON
113 gas
Security -
5” lockout time
no
I
85°C Limit
Thermostat
105 / 110°C High Limit
Thermostats
2l3 Orange
Solenoid
Thermistor
I+
F
-ig. 7
L
1.6.6 Safety Controls
In addition to the normal safety controls the STERLING FF
incorporates the following feature.
Should the central heating water flow reduce to below 3OC’
Uh (1,l gal/min) the gas supply to the burner is turned 01
via the flow switch (No.31 - page 6). see figs 5 & 6 (37).
8
1.6.7 FUNCTIONAL FLOW WIRING DIAGRAM
1.6.7
PRESSURE
WATER FLOW
BOILER
POTENTIOMETER
HEATING
bk
9e Y
L 3A L
L-l
LINK or EXTERNAL
-......-,. _I.”
INTER SWITCH bk
2A 2A
hY-
PRINTED CIRCUIT BOARD
,-CHANGE OVER VALVE,. .
MICROSWITCHES :
STAT -
HIGH LIMIT
SECURITY (2)
RESET
SWITCH
N N
k
P
BOILER
THERMISTOR
HEATING
-w w ^C^. .-.-I
rzl
w
r
SkG”Hl I I
SOLENOID
VALVE
IGH RATE
IGNITION ELECTRODES
FLAME
SUPERVISION
1
I
Fig. 8
b = blue
bk = black
br = brown
ge = green
gr = grey
or = orange
r = red
v = violet
w = white
y = yellow
9
1.6.8 ILLUSTRATED WIRING DIAGRAM
FAN
\MESUPERVlSlON 11 , 1
HIGH LIMIT
THERMOSTAT 110”
BOILER THERMISTOR HEATING
240V
50Hz
I
I
L
N
I
Ph
1
EXTERNAL CONTRO
II
ROOM TH
- -
III II II
I
r
UJ
s
II
WATER FLOW SWITCH
I
BOILER POTENTIOMETER
HEATING
---
SELENOID VALVE
-ig. 9
.
HIGH TENSION
II
.,” TRANSFORMER -
ALL CABLES ARE 240V EXEPT WHERE THEY ARE INDICATED 24V
SELECTOR SWITCH t+#-.~ 11
1
tn “AL”q./- ORI!
I-
1111
10
Hki LlMlT
(MANUAL RESET) 105”
SECURll-Y
2
2.1
2.2
INSTALLATION REQUIREMENTS
General
The installation of the boiler must be in accordance
with Gas Safety (Installation and Use) Regulations,
Building Regulations and current Byelaws of the Local
Water Undertaking. It should be in accordance also
with the current BS Codes of Practice and the British
Gas Specifications for Domestic Wet Central Heating
Systems and any relevant requirements of the local
Gas Region and Local Authority Building Standards
(Scotland) Regulations and the Safety document 635
the Electricity at Work Regulation.
Detailed recommendations are stated in the following
British Standard Codes of Practice:
B.S. 6891, B.S. 6798, B.S. 5440 : 1 and 2, B.S. 5449: I,
B.S. 7593, BS 5546B.G.DM2, B.S. 4814. B.S. 7074 1
e 2, B.S. 7671.
Note : Gas Safety Installation and Use Reg. It is the
law that all gas appliances are installed by competant
persons in accordance with the above regulations.
Failure to install appliances correctly could lead to
prosecution. It is in your own interest and that of
safety to ensure compliance wlth the law.
Location
The boiler is not suitable for external installation. The
position chosen for the boiler must permit the
provision of a satisfactory flue termination. The
location must also permit adequate space for servicing
and air circulation around the boiler. The surface on
which the boiler is mounted must be of non
combustible material.
The boiler may be installed in any room or internal
space although particular attention is drawn to the
requirements of the current B.S. 7671 and, in
Scotland, the electrical provisions of the Building
Regulations applicable to Scotland, with respect to the
installation of a heater utilising mains electricity in a
room or internal space containing a bath or shower.
Where the installation of the boiler will be in an
unusual location special procedures may be necessary
and BS 5546 gives detailed guidance on this aspect.
A compartment used to enclose the boiler must be
designed and constructed specifically for this purpose.
An existing cupboard or compartment may be used
provided that it is modified for the purpose.
Details of essential features of cupboard/compartment design are given in BS 6798.
2.3
2.4
Water Circulation System
The STERLING FF is suitable for SEALED SYSTEMS
ONLY and should be installed in accordance with the
relevant recommendations given in BS 6798, BS
5449:l (for the smallbore or/and microbore systems)
and the British Gas Specifications for Central Heating
Systems.
Sitfng the Hue Terminal
Refer to section 1.4 for details of wall thicknesses
which can be covered.
Detailed recommendations for flueing are given in BS
5440 Pt 1. The following notes are intended to give
general guidance.
The boiler must be installed so that the ffue terminal is
exposed to external air. The boiler must NOT be
installed so that the terminal discharges into another
room or space e.g. outhouse or closed in lean-to. It is
important that the position of the terminal allows a
free passage of air across at all times. The miniium
acceptable clearances from the terminal to
obstructions and ventilation openings are specified
below (fig. 10).
Horizontal Flue
Terminal positions
A - Directly below an opening, windowsetc
or adjacent to an opening . . . . . . . . . . . . . . . . . . . .
B - Below gutters soil pipes or drain pipes . . .
C - Below eaves . . . . . . . . . . . . . . . . . . . . . . . . ..200
D - Below balconies or car port roof . . . . . . . . . . . . 200 mm*
E - From a vertical drain pipe or soil pipe . . . .
F - From an internal or external corner _....... 300 mm*
G - Above ground roof or bs.lcony level . . . . . . . 300 mm
H - From a surface facing the terminal. . . . . . . . 600 mm
J - From an opening in the car port
(e.g. door or window) into dwelling . . . . . . . . 1200 mm
K - Vertically from a terminal on the same
wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1500
L - Horizontally from a terminal on the
same wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* ( 107 mm) minimum clearance using
kit No. 76216.CK)(G.C.264833)(seesect.h 14.3,fig.3c)
Vertical Ffae
Terminal positions
M - Above intersection with Roof . . . . . . . . . . . . . . . .
Mii clearances
300 mm
75 mm
mm*
75 mm
mm
300 mm
Min clearances
150 mm
Fig. 10
L
11
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