s Sterling System Boiler
Room Sealed Fanned Balanced Flue
Sealed System Boiler
GAS SAFETY (INSTALLATION AND USE1 REGULJYTIONS.
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)
Installation and Servicing Instructions
(leave these instructions with the user)
Looktng Good.Heathg Better
Health and Safety Information
Paae
1
1.
INTRODUCTION
1.
1.1.
1.2.
13.
1.4.
1.4.1.
1.4.2.
1.43.
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
Cl~CeS
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 Wing Diagram Fig. 8
illustrated Wiring Diagram Fig. 9
2. INSTALLATION REQUIREMENTS
2.1. General
22. Location
23. Water Circulation System
2.4. Siting the Flue Terminal Fig. 10
25. Air SupPlY
2.6. Electrical Supply
2.7. Gas Supply
3.
SYSTEM GUIDANCE
3.1.
(Z&mrai
32
System Controls
3.3.
pump Fig. 11
3.4.
Expansion Vessel
3.5.
Mains Water Connection
3.6.
Filling and Recharging Fig. 12. Fig. 13 @age 12)
3.7.
Make up System
3.8 .
Pipework
3.9.
Domestic Expansion Vessel
39.1.
Boiler Replacement
392.
Existing systems
3.10
Cyhnder
3.11
Inhibitors and Water Conditioners
3.12
Add on Devices
3.13
Heating
and H&Water Systems Fig. 14. Fig. 15, Fig. 16. fig. 17
3.14
Shower Application Fig. 1%
2
2
3
3
3
4
4
4
5
6
7
7
7
8
8
8
9
10
11
11
11
11
12
12
12
12
13
13
13
13
13
13
13
13
14
14
14
14
14
15
16
(9
cclLm2m (con0
4.
INSTALLING THE BOILER
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.
General Information
Positioning the Boiler Fig. 18
Rear Outlet Flue Fig. 19
Side Outlet FIue Fig. 20
Jig Plate Fig. 2 1
Gas and Water Connections Fig. 22
water COMtXtiOIkS
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
&MeCtiOllS fig. l?7
Vertical Flue Figs. 28,28a, & Fig. 29
5.
EXTERNAL CONTROLS
5.1.
Programming and Zone Valves Fig. 30
52. Honeywell & Sat&well Controlled Zones Fig. 31
53.
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
22
22
22
22
To comply with the Control of Substances Harmful to Health Regulation .1988
provide information on the following substance that is contained in this appliance.
Combustion Chamber Lining
Material
Alumino Silicone Fibre
we are required to
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.
1
L INTRODUCIIOiN
The STERLING SB is a waft mounted, low water content
fanned balanced flue appliance suitable for
central
heating
and hot
water
via a fast recovery indirect cylinder. The
maximum output is 17.5 kW (60,ooO Btti) and 23.3 kW
WWOO Btwh).
The boiler is designed for sealed systems only and inciuded
in the appliance are the expansion vessel, circulating pump.
optional 3 ports mid position valve, a pressure gauge,
Safety wtlve. electrical amnection and plug by-pass.
1) The standard 5ue assembv supplied with the boiler is
100 mm (4
ins) diameter pipe, it can be directed to the rear
or to the left or right and, can be extented to a maximum
length of 3 meters, or 1.6 meters 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 ffue option available is 12s mm (5 ins) diameter
pipe which can extend up to a maximum
of
9.5 meters
straight. 8 meters
with 2 x 45” bends. or 6
meten with 2 x
90” bends (see section 1. 4.4).
Special
futures
fndud- -
- Fuky range rated between 10 to 23 kW for SB 80 and 9
to 17.5 kW for SB 60.
- High effidency.
- Fixing piate.
- Adjustable ffow
temperature central between a
nominal
60” C and 82” C.
- High limit tllermostat.
- Built in by-pass.
- Integral pump.
- expansion vessel.
GUARANTEE
The manufacturers guarantee on this appkance is for 12 months from the date of purchase. The guarantee is nulle and void.
if the appliance is not installed in accordance with the
recomm
endations made herein.
1.1
DIiENSIONS
Fig. 1 .
R ’
-
k
SIDE OUTLET
A
820.5
B
391.0
C
365.0
D
100.0
E
169.5
F
654.5
G
100.0
H
50.0
J
260.0
K
972.5
L
13.0
M
61 .O
N
30.0
P
152.0
R
112.0
mm
in
32.3
15.4
14.4
4.c
6.7
25-
4
ii;
10.2
38.3
0.5
2.4
1.2
6.0
4.4
2
:
i
1.2 TECHNICALDATA
Cued hutiag
Maximum input.. ........................
Maximum output..
......................
Gas mte (maximum) ...................
Burner pressure.. ............
..‘........
..
Minimum input..
.........................
Minimum output
........................
Gas rate (minimum) ...................
Bunter pressure.. ........................
Minimum Bow rate
.....................
lbfaimurn pressure..
...................
k the muimuzu preasra loss 04
Temperature of the products of
combustion :
..............................
The CO content of the dry &ee air
products of combustion
: ............
STBRLING SB 80
I
STERLING SB 60
1
26.1 kW
23.4 kW
2.63m3/h
9mbar
12 kw
1okW
1 .O m?h
1.3 mbar
5oom
2.5 bar
1
89058 Btulh
19.80 kW
67561 Btulh
79845 Btufh
17.75 kW
60566 Btufh
92.98 ft3/h
2 m3/h
70.71
fl3h-i
3.6 in wg
7.2mbar i
2.9
in wg
40946 Btu/h
11.10 k
37875 Btti
34122 Btwh
9kW
30709 Btw-h
35.31 fwh
1 .O m3/h
35.31
A3ll-l
0.5 in wg
1.7 mbar
0.6 in wg
1.8 gaYmin
3OOvh
1.1 gavrnin
36.5 psi
2.s bar
36.5 psi
It! flue
I
0.0136%
Natud gas
injectors
number
14
12
Manifold injectors . . . .._....... l........
1.28 mm 0.05 in
1.28 mm 0.05 in
Manifold restrictors .._.._._. . ..__.......
4.7 mm 0.18 in
3.8 mm 0.15 in
COMUtiOllS
GaS
.............................................................. 22 mm copper
Heating
a0w
(2) ........................................... 22 mm copper
Heating return.. ............................................
22 mm copper
Electrical suppiy 230 V - 50 Hz. fused at
3h
(on command box)
Electrical consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . ..-... 195 watts
Intemaliyfused.twoat2A(BS4265)
Weight . . . ..__........._...._._.....__._................_._..... 42 kg 92.4 lb
Water capacity . ..__...__....._._........................... 4 litres 7 pints
Ignftion - HONEYWELL
Ignition electrode - SAPCO, ARC0
IgEM pm3he - SAPCO. AFCO
Bokr lhnlt thermostat - ELhlWOOD / TOKOSWITCH (85X)
Bof!uregufaffoll thamostat - Mrr
safety amrhut thcrmo8tat ( E7,hMaD- - (105°C)
(manual reset)
Gasvahre-HONEYWEU/SIT
Fan motor - SRI.
Prusom switch - DUNGS / TRIDELTA / HONEYWEEL .
Pump head - GRUNDFOS UP 15E.O
-~fnftfrIchupcpiamrr
- 0.65 bar (9.6 psi)
IbmesticqansionvuseIiuItialchagc~-2bar(3Opsi)
1.3
1.4
MINIMUM CLEASWCES AROUND BOILER
Top above
air duct . . . . . . . . . .
5omm (2in)
Bottom beIow case . . . . . . . . . .
150 mm (6 in)
skies
.*.............................
1OOmm (4in)
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
600 mm (24 in)
WAUIHICKNESSBS
The standard ftue assembly can accomodate the folkwing thicknesses.
Rear:from40mrnto576mm
Siie:~om40rnmto392mm
(this allows for a
minimum clearance of 100 mm between the appliance and the side wali. As this dimension inaeases.
so the maximum side wall thickness available decreases).
&fern&n flue assemblies are available to accomodate wall thicknesses of :
Rear: ~om577mmto2876mm
Side : from 393 mm to 2692 nun
IMPORTANT NOTE : The extension ducts supplied, up to a maximum of 3, will in fact pennit a greater length than
indicated to be covered. The ducts MUST be cut so that the
rrkdrnurn length kom the oentre line of the fiue turret
to
the
outermost point of the air duct DOES NOT MCEED 3 metres hodzontai. Greater length must not be used.
See sections 1.41 1.42. 1.4.3.
3
i
1.4.1
1.4.2
I
1
REAR FLUE OUTLET HORIZONTAL
To cut ffae uaembfy
to
kngrh
- Measure walI thickness 0.
- Add 74 mm. this wiii give rquired length (L).
- Mark plastic air duct for Iength (L) and cut off
surplus (kern plain end).
N.B.
If extension sections
are
used ensure these are
- firmly pushed together. see figs. 3b and 3c and a faii of 5
mm per metre length should be provided (see section
- Cut off same amount from ak.&niurn flue duct
Flue extension accessory
Part No. 62823.00
REAROUWETASSEYBLY
:ig. 2
SIDE FLUE OUTLET HORIZONIZL
external
internal
To cut flue urrmbfy
to
laq@.h
- Measure from external wall face to centre fine of
STERLING SB and substract 37 mm (this will gii
required length Q.
- Cut off surpIus from plastic air duct (pIaii end).
N.B. If extension sections are used ensure these are firmly
pushedtogether.seeEgs.3band3candat%iIof5mm
- per metre Iength should be provided (see section
0’ - Cut off same amount fiorn aluminium
flue duct (plain
- Fit the rubber sleeve between the flue turret and the flue
Flue extension aacessq
Pm
No.
62823.00
RASTICAIRDUCT
ALUMINIUM
FLUE DUCT
OlHERFLUEARRBNGEMENlS
BORIZONIAL
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 (GCNo
264 833).
3. Appliance is normally supplied packed with standard 650 mm straight 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 Iengrh
Ll + L2 should not exceed 1.6 metres horiron-
Fig.3c .
W
4
1.4.4
VERIICALFLUEARR&NGEMENTS
Fii.3d
Fig.3f
,
m
Fig . 3 g
P
a)
Strdg&t
ffae (fig. 3 d)
1) Adaptor.
2)
F~ensions (9.5 m
maximum).
3) Roof Bashing.
4) Terminal
6) Reducer.
b) Fke wkb two 4S” bends (f& 3 c)
1) Adaptor.
2) kknslons (8 m maximum).
3) Roof tlashing.
4) Term&L
5) 45” bend.
6) Reducer.
c) Flue wkh four 4f” beads (ffg. 3 I
and 3 g)
1) Adaptor.
2)Extensions(6mmaximum)fig.3fand3ginclu-
dinghorizontal(2m~um)fig.3t
3) Roof flashing.
4) TemGnaL
5) 45” bends (x 4
Wum)f&3fand3g.
6) Reducer.
With the aceptlom
of
(3) roof fbhfag and (4) taml-
aal, all
otha
fftthgs arc designed for
fatand
fnrtal-
kttotl o*.
N.B. In these two anangements figs. 3 f and 3 g. the
total length of straight extensions ~~l~dsf not exceed 6
metrewitha maximumof4x45”bendsor2x90°
bends.
Horizontal mn must not exceed 2 meters.
Important
: When the vatkal he exceeds 5 metem,
pzwidonwillhavetobemadctodnfatheomdearrte.
5
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