Page 1
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
Page 2
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
Page 3
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
Page 4
Page 5
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
Page 6
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
:
Page 7
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
Page 8
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
Page 9
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
Page 10
1.5
DESCRIFTION.OF COMPONENTS AND LOCATION
Fig. 4
The appliance is mounted in a steel case which has a white
epoxy resin paint tinish.
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. bmhustion chamha :
This is as.sembIed kom a number of components mounted
onto the chassis. The Gent panel is simply removed for seti-
cing complete with the expansion vessel, a hook is fitted
below the appliance to accept and retain the panel during
sticing.
4. Expa&on
vessel
: (not illustrated)
The expansion vessel has a capacity of 5.4 litres (1.19 gal)
and is sized for a non-r& system water content where the
Ioad is equiAent to the maximum output of the boiier. The
charge pressure is 0.65 bar.
5. Flame supavhbn ddce (not illustrated).
6. Mrdtigas bmna comprising : stainless steel blades (14)
and a manifoid with injectors (14).
7. Gas section including main soleno’fd valve and addditionai
security soleno’fd valve.
8. Three ports mid positbnee (Opho~O
9. Electrkfal box aantahhg :
Mains
connection
Fuses
ControI box
Connections for external controk
Connections for fan and pressure switch
Connections for pump
Connections for optional three ports mid position
valve and pmgrarnmes
10. Connection
for
gas valve.
11. Grundfos pump motor 15150
12. Ak
separator
and vent dire* connected to the pump
inleL
13. Regafation screw to adjust output to heating of boiler-
14.
Heating body com~g :
Copper tinned ‘tube heat exchanger protected with silicone
resin paint. Combustion chamber in aluminium
coated steel.
Combustion chamber hing - ceramic fibre pads.
15. Hig& Emit themostat (manual reset).
16. flow for
hot water cylinder
(optional).
16. Gas seAee tap (no4 illustrated).
21. Lock out hadlator light.
22. Main ON/OFF switch.
25. Thermostat
to regulate flow tempemture.
27. Air pressure switch.
28, Fuse.
29.
Pressure gauge.
30.
Data badge posMon (on sealcxf aver).
Page 11
1.6 DESCRIPIIONOFOPERAIION
The STERLING System Boiler provides centrai heating
and hot water in conjunction with a fast
recovery indirea
cylinder. The selector switch can be set to hot water only
when using the 3 way optionaI vaIve or
to
heating and
hot water. If the valve is not fitted when the sutch must
to set to hot water ad-he&.
1.6.1 cENTRALHEKIING~seeiig.
5)
When external controls demand heat the boiler
thermostat energises the central box and the fan
operates to purge the combustion ciamber.
High tension voltage
is then
applied to the ignition
electrode and a stream of sparks pass from the ekctrode
to the bumer assembly. The gas vaIve then opens and
allows l/3 rd of the
maximum gas to pass to the burner
for ignition. Once the flame has been proven by the
ionisation circuit, the gas rate increases to the adjusted
set rate.
At the same time the pump circuIates water around the
heating system, which retums to the boikr via an air
reparator. an air purger, and an isolating vaIve
contraining a filter. It then passes through the heat
exchanger where
it
is heated, and on to the radiator
circuas via the 3 way v&e if &ted.
There
is
a manually adjusted by-pass connected
between the flow and retum.
Temperature central is by means of a thermostat,
between 50°C and 82°C
Expansion Provision is avaiiable via an expansion vesseI
connected to the return valve.
When The
BOW temperature
nEh%es the set level. fhe boiler
thermostat de energises the control box ad the burner is
extinguished and the circulations Ponys contunues to
operate. Of extemed controls are satisfied then the burner is
extinguished ad the ciradating pump stops.
1.6.2 HOTWAIER~
optiona1seetig.6)
When extend contds dknande heat the ix&r thermostat
energises the controI box and the fan operates to purge the
combustion clamber. High tension voltage is then appiied to
the ignitim electrode and a stream of sparks pass fan the
ekctrode to the burner assembIy. The gas vaIve then opens
and aIIows l/3 rd of the
maximum to pass to the burner for
ignition. Once the fIarne has been proven by the ionisation
circuit, the gas rate increases to the adjusted set rate. At the
same time the pump circuIates waters, around the primary
circuit of the sekcted hot water cylinder, which returns to
the boiler via an air separator, an air purger and an isolating
valve contmining a 5Iter.
It then passes through the hect exchangeur where it is
heated and on
to the primary
circuit of the se&ted hot
water cyIinder. via the 3 way vake. Temperature control is
by means of a thermostat between 50°C and 82°C but an
aditional cyIinder thermostat is recomended.
Expansion provision is avaiIable
via
an expansion vessel
connected
to
the return w&e.
When the ffow tempetature reaches the set Ievef the boiler
thermostat de energises the
control
box and the burner is
extinguished and the circukting pump continues to operate.
If the extemai controls are satisfied then the burner is ext
inguished and the circuIating pump stops.
Central Heating
Fig. 5
Hot water
I
Fig. 6
Page 12
1.6.3
GAS (see figs. 5
and 6)
1.6.4
circuit. If the main burner is not established after 5
seconds then the boiter tbils safe to lockout and has to be
WhenUlegassenriceistrtmedwahasaew~etothe
on position gas is adrniied to the gas section.
reset
manuaEy
by operating the main ON / OFF switch.
When there is a demand for heating or hot water, the gas
Mhre is energised and it aIIows gas to pass to the burner.
Simultaneously the high tension voltage produces a
stream of sparks between the two ignition electrode
which ignites the gas, after few second the gas rate
increases to the adjustested rate.
The flame supervision is controlled by an ionisation
FUNCTIONAL DIAGRAM
SSEC LuxcutllhE
MANlMLREs3tw
PowR.swTTa4
(optional)
I
3 ports v&f0
8
1
Page 13
ELECTRICAL FUNCTION DLKGRAM with pack
programmer
I
I
It
d!
main on/+ 4-k
I+
-.. --..-..
L-
/
\/ I -
I I
I-1
3 mid
position
control
- box
1.6.6 ELECTRICAL FUNmON DIAGRAM with-t pack
main on/off 8wkh
L
47
I
mom
stat
0’----
St-
&T
1
N
E___1,,
I
gas valvas
>
P-m
8witdl
ti
i
control
’ box
9
Page 14
1.6.7 XLLUSIRAIEDWIRINGDIAGRAM
Flame supervision
Safety overheat
Boiler limit stat
thermostat
(automatic RESFF)
(manual RESET)
E
Bk-
TO
oktrIal
. -
N
Ignition
electrodes
Lock out
indicator
light
Pressure switch
rw
Gas valves
Pump
Er Boiler regulation stat
IL-
B = blue
Bk =
black
Br =
brown
Ge=
green
MP
mauve
Or P
orange
R = red
v =
violet
W=
white
Y
= yellow
Page 15
2
INSTALLRTION REQUIREMENTS
2.1
2.2
GENERAL
The installation of the boiier must be in accordance
with Gas Safety (Installation and Use) Regulations.
Building Regulations and current 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 rekvant requirements of the local
Gas Region and Locai Authority Building Standards
(Scotland) Regulations and the Safety document 635
the Electrkity at Work Regulation.
Detailed re
commendations are stated in the following
British Standard Codes of kacticez
B.S. 6891. B.S. 6798, B.S. 5448 : I and 2. B.S. 5449: 1.
B.S. 7593, BS 5546 B.G.DM2. B.S. 4814, B.S. 7074 1
e
2.
B.S. 7671.
Note
: Gas Safety
InstaUation
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 with the law.
LOCATION
The boii 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 bcder 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 utilisii mains electricity in a
room or internaS space containing a bath or shower.
Where the installation of the boiler wili 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 boiir must be
designed and constructed spe&caRy for this purpose.
An existing cupboard or compartment may be used
provided that it is
mod&d
for the purpose
Details of essential features of cupboardkompartment ciesiin are given in BS 6798.
2.3
WATER CIRCULATION SYSTEM
The STERLING SB is suitable for SEALED SmS
ONLY and should be installed in aaordance with the
relevant recommendations given in BS 6798, BS
5449:1 (for the smallbore or/and microbore systems)
and the British Gas Specitiations for Central Heating
systems.
2.4
SITING THE FLUE TERMINAL
Refer to section 1.4 for details of wall thicknesses
which can be covered.
Detailed re
commendations for ffueing are given in BS
5440 Pt 1. The following notes are intended to give
genefai guidance.
The bder must be instaUed 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 minimum
acceptable clearances from the terminal to
obstructions and ventilation openings are specified
below (tig. 10).
Horizontal
Flae
Terminal podtlonr
Mhlclrorances
A - Lkedy
below an opening, windowsetc
or adjacent to an opening . . . . . . . . . . . . . . . . . .._.. 300 mm
E - z2f zu soil pipes or drain pipes . . . 75’mm
-
. . . . . ...‘-....‘....-................‘-.’-”
200mm*
D - Below balconies or car port roof . . . . . . ..__.- 200 mm*
E - From a vertical drain pipe or soil pipe.... 75 mm
F - From an internal or extemal comer _.._.... 380 mm*
C - Above ground roof or balcony level _..._.. 300 mm
H
- From a stice 4dng the terminal . . . .._.._ 600 mm
J-Fromanopeninginthecarport
(e.g. door or window) into dwellI@ . . . . . . . . 1200 mm
K - Vertically fom a terminal on the same
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..___........._..-.....-...
1500mm
L-Horizontallykomaterminalonthe
samewall
. . . . . . . . . . .._.....__......-...............-...
3oomm
l
(107mm)minhxnckamazus’~
kitNo.76216.oO(c.C264833~see~14~.~.~~
Vextical Flae
nrdnd posMons
Mincf~cu
M - Above intersection with Roof . . . . . . . .._...._. 150 mm
1 Fig.10
Page 16
BUILDING REGUIATIONS excerpt.
&provaf document-j Part B 1.4 (C) (D).
c) Protect with a terminal guard iitted centrally over
the terminal if it could come in contact with people
near the building or Ix subjected to damage.
D) Designed so as to prevent the entry ot any matter
which might restrict the flue.
(A terminal guard GC. No 381782 is available from).
Quinnel Banet & Quinnel Wiiorks
Old Kent Road
London SE15 INL Tel 071-639-1357
The air inleVoutlet duct and the terminaI of the
appliance must not be closer than 25 mm (1 in) to
any combustible material. Detailed recommendations
on the protection of annbustiable material are given
inBS544OPtl.
IMPORTANT NOTICE : TTMBER FRAMED
HOUSES
~THEAPPLIANCEISTOBEFllTEDINAAER
FRAMED BUILDING IT SHOULD BE FITTED IN
ACCORDANCE WITH THE BRITISH GAS
F’UBLKFJION - “GUIDE FOR GAS INSTALIAl-lONS IN
TIMBER FRAMED HOUSING’ reference DM2. IF IN
DOUBT, ADVICE MUST BE SOUGHT FROM THE
LOCAL REGION OF BRITISH GAS OR COR.G.1.
2.5
AIR SUPPLY
The room in which the boiler is instaIled does not
require a purpose provided air vent
Ifthe boiler is installed in a cupboard or
compartment
pemxment air vents are required in the cupboard or
compartment. one at high IeveI and one at low leveI
eitherdirecttotheout.sicIeairortoaroom.BothhIgh
and low Ievel air vent
5
same space
must cornmu
ni
kate with the
I
Podtioaofwab
240 an2
240 an2
180 an2
18QUll2
Akdhctfmm
oatddr
120 cm2
120 a-n2
9oan2
9oan2
2.6
EIectrkaI StfppIy
- This
appliance must
be earthed.
- All Wiring external to the appIiance must conform to
the cummt B.S. 7671.
-TheSTERLJNGSBrequiresa230V-50HzsuppIy..
- Connection of the appliance and any system controls
to the mains supply must be through a common
isolator and must be fused at 3Amaximum.
Thii should preferabiy be an unswitched shuttered
socket outlet and 3 pin plug to BS 1363. Altematively.
a double pole isdating switch may be used, provided
ithasa
minimumcontactsepalationof3mminboth
poles. The isolator should be cIearIy marked showing
its purpose, preferably positioned close to the
appliance.
-Fuse the supply at 3A.
-The supply cord must be 0.75 mm2 (24 x 0.2 mm)
three are to BS 6500 Table 16.
2.7
3
3.1
GAS SUPPLY
The STERLING SB requires:
The meter and suppty pipes should be capable of
delivering this quantity of gas in addition to the
demand from any other appliances in the house
The complete Installation must be tested for
soundness
z-described in BS 6891.
SYSTEM GUIDANCE
GENERAL
The Iow water content SIERUNG SB boiler indudes
an expansion vessel, safety overheat thermostat,
safety We. pressure
The ffow temperature is adjustable and gives a
nomInaI 82 “C (180” F) on its maximum setting.
Detailed recommendations for water circulation are
given in BS 5546. When the boiler provide hot water,
a fast recovery cylinder will be used, detailed
recommendations of this application are given in
sections. A cylinder thermostat is recommanded.
Separate time and temperature control over hot water
generated in this way CM be achieved by the use of
the optional three way ties in a conjunction with a
cylinder thermostat and programmer.
12
Page 17
3.2
3.3
3.4
When replacing an existing cylinder storage system
with STBIUNG SB it is essentiaI that all redundant
pipuwork
is
removed and dead legs eliminated.
In properties where there are multiple drawoff Points
on different levels consideration should be given to
the use of non-return -Ives in the secondary hot
water system to avoid active dead lelgs. No nonreturn valve should be less than 1 m (3 It) above the
top of the appliance and IdeaIly should be as dose as
possible to the hot water outlet.
SYSTEM CONTROLS
The boiler is electricany controlIed and is suitable for
most control schemes
currently available including
thetmostatic radiator valves and motorised valves.
The boiler is fitted with a Grundfos UP. 15/50 pump
head. The graph (IQ. 11) indicates the residual head
avaiIable for the system.
When using motorised valves the controIs should be
arranged to switch off the boiler when circuits are
Fig. 11
satIsfieId. The boiler requires a minimum flow rate of
500 L/h (2.2 gaI/min) and consequently, if
thermostatic tad&r valves are &ted to all radiators,
ad&sment
must
be made to the internal by-pass to
ensure that the boiler operates correctly (see Iig. 17).
P-P
EXPANSION VESSEL
The expansion vessel which is fitted on the front of
the combustion chamber accomodates system water
Flow rata in g.p.m.
Plow rat. h Iitrwltour
expansion. The vessel has a capacity of 5.4 litres
(1.19 gals) and is charged to a pressure of 0.65 bar
(9.7 p&i.).
THE CONNECTION IN THE CENTRE OF THE
EXPANSION VESSEL IS A CHAECING AND NOT
A
VENT FOINT.
At the design flow temperature and the initial system
pressures quoted the maximum allowable system
vdume is 75 litres. The water volume is not known
and cannot be accurately assessed from
manufacturers data the foIlowing volumes may be
3.5
MAINS WATER
CONNECTION
3.6
There shall be no permanent connection to the
Heating System Pipework for 6Iliig
or
replenishing
without the approval of the Local Water Authority (see
Byelaw No.14 and figs. 12 and 13).
FILLING
POINT
Fii and rechargmg can be done :
1) Through a temporary hose connection to mains
water.
A stop-valve should be fitted to the service main outlet
and a double check valve assembiy and stop-valve
should be Pted
to
the system side of the temporary
hose (see fig. 12).
2) A cistern used for no other purpose
co~ected
to
the mains water. The static head provided by the
dstem m be suf6dent to satisfy the designed initial
system pressure. The suppfy pipe from the cistern
should include the double check vaIve assembIy and
stopad (see fig. 13).
3.7
MAKEUPSYSTEM
Provision must be made for
replacing
water lost from
the system indicated by a reduction in pressure
shown on the pressure gauge. Recharge through the
6IIing point (see
section 3.6).
3.8
PIPEWORK
used to give
a
conservative
estimate of the system
volume.
%kr . . . . . . . . . . . . ..__......-....................-.... 4
litres (0.8 gals)
SmaIl bore pipework
. . . . ..-.......... 0.3 litres (0.07 g&i)
per0.292 kW
Mibore pipewo* . . . . . . . . . . . . . . . . . . . . . . . . . .7
I&es (1.5 gals)
steel
panel radiators
._......_............. 2.3 litres (0.5 gals)
per 0.292 kW (1000 Btuih) of system output
Hot water cylinder
. . . . . ..-...--........... 2
IitIes (0.44 gals)
If the volume exceeds 75 litres an additional vessel
wilI be required t&d in the flow Erom the appliances.
Refer to BS 7074 Pt. 1 or BS 5449 for details of siziig.
Pipework can be of copper or’suitable plastic, smaIl
bore or microbore with capillary or compression
jointing to a high standard. Leak seaIant must not be
used in the system.
13
Page 18
Air inlet
valve
Double check .
valve assembly
Hose
valve
i-
Test cock
Temoorarv
(a) Non-automatic filling and make-up. Temporary hose tilling loop avaible, Pt.No.CHL112
Overflow .__......
-I-
I
..i_ .i .
. ..i
L..... . . . . . .
. . . . . . . . _......
,:.:.:.:.:.:.:.
Double check
Hea;:;: ~
valE?blY ~~~
Test cock
-_
I
Fg. 13
(b) Automatic filling and make-up.
J
%o be located
above highest
point in the
system and
satisfy the
designed initial
system pressure
3.9.1 BoUer replacemAt (retrofit)
Inanddsystemwheretheboilerisbeingreplaced.
we recommend the use of a strainer. fitted with a
drain tap on the heating return. designed to retain
scale partides and other solid debris. It is good
practice to use a chemical deaner with a fIoctuating
agent, used as recommended by the cleanser
manufacturer, to clean the system before the old
boiler is removed. (see BS 7593).
3.9.2
Existing
llystems
Valves and joints should be carefully checked for leaks
and the appropriate a&on should be taken either as a
repair or replacement. The old open system has
probabIy onIy been subjected to a pressure of 0.4 bar
or less. When you clmnge to a sealed system where
thechargepressurewiIIbe1.Obarandtherunning
pressure exuxding 1.5 bar. consideration should be
given to the repIacement of radiator valves with a
pattern capable of s&g at the higher pressures.
3.10
Cylinder
Whexe a domestic hot water cylinder is used with the
STERLING SB it must be of the indirect and fast
recovery
type to BS 1566 Pt 1
Single
feed cylinders
are not suitable for use with this appliance. 3%~ and
return pipewak to the cyIinder should be in 22 mm
Pipe-
3.11
Inhibltom and water conditioners
(see BS 7593)
.
Chaffoteaux
et Maury generally recommend the use
3.12
of inhibitors In systems using the STRRLTNG SB boiler.
The following are the appliance manufacturer’s
reoommetxkttions :
I) Use only a British Gas or similar approved inhibitor.
These manufacturers can assist with the selection.
Grace -rn Ltd. Wiies. Cheshire WA8 8 UD
Telz 051424 5351.
Femox Manufacturing Company Limited. Britannica
Waks. Clavering. Essex CBI! 4QZ
Tel: 0799 085811.
2) Use only the quantities specified by the inhibitor
manufacturer.
3) Cleanse the system as required by the inhibitor
manufacturer.
4) Add inhibitor only after flushing when tinally re-
fining the system.
Add-on devtces
It is important that no external control devices e.g.
economisers be directly fitted to this appliance uniess
covered by these installation instructions or agreed
with the manufacturer in writing. Any direct
connection of a control device not approved by the
manufacturer could make the guarantee void and also
inkinge the Gas Safety (Installation & Use) Regulations.
14
:
Page 19
I
Heating 8 stored ho
STERLING S8
water - spring return
I L f
I
valves onlv
I
STE
Heating & stored hot
iRLlNG SB
water using flow share
I 1
relay required
I
FIg.YS
I
STERLING SB STERLING SB
Remote by-pass Remote by-pass
built in by pass built in by pass
remote
by pass
remote
by pass
with us velve with us velve
3.13
Heating
and hot water systems
Figs. 14. 15. 16 and 17 indicate various layouts for
the production of hot water. It is recommended that
only a fast recovery indirect cylinder is used and
circumstances may from time to time dictate that a
special s&waled heat exchanger in an indirect
cyiinder may be desirable.
When using thermostatic radiator valves, the
minimum flow rate through the boiler must be
mainkned
at aII times. The build in by-pass is set in
the closed position during manufacture and may
require ajustment. Atecnativ~ a remo!e by pass may
be instakd (fig.g.;r).
Page 20
4
INSTALLING THE BOILER
4.1
4.2
A Vertkd flat area k required for the boiler: 1122 mm high x 591 mm wide (44 in x 23.25 in). The surface on which the
boiler is mounted must be of a non reverberating and
of
a non combustible materiai. The appliance is supplied in a two
cartons which contain :
11 The bdcr wltb all parts artached and fixing kit. uxaprhimg
of :
,
1
- The
chassis with all funhnal parts attached.
2
- Casing
comprising : 2 side panels
1 &It panel
1 control panel
3 - Top support plate :
4 - Box containing :
water cormections and washers
gas connection and 6ltec’washer
control knob and gas service tap
safktyvabe
wan plugs
saews and fixings.
2) The hohntaf floe
assembly coom~ of:
1 - RueTm and Flue duct section :
-Plasticwaulinerwithterminai
7 Pbstic turret cover ( garden)
2-Fkticbagamtaining:fIu2lockingring
-‘(y&q
- 2 gaskets : one cork and one rubber
- 4 mounting saews
3 - The vrrtical flue d8ptor amlprising
- adaptor assembly
- 2 gaskets : one cork and one rubber
- 4 mounting screws
NB. (i) Flue accessories are not supplied as standard, and must be ordered to suit (see section 1.4)
PosMoning the bo&!f
0107,,1,
.
---
-T-
--
‘. .’
;F
169.5
c----- &- ““,
f
I
a) Select
the
location for the boiler referring to the
dimensions shown in 1.1 and 1.3 terminal
location
pdtions (2.4 - Eg. 10). b) Check flue length (see 1.4 6gs. 2 and 3).
c) Check
clearance on external wall for flue terminal
position (see table 2.4 - 6g. 10)
Fig. 18
Rear
outlet LIrrc
a)MarkverticaicentreIineforboiIeronwalL
b)
Mark horizontal centre iine for 107 mm (4.2 in) dia
flue opening and one for bracket 6xing screws (A).
c) Using bracket as template mark 2 Exing points (A).
cf) ya. $ for the ffue opening using a 107 mm (4.2
c) DdI 2 fixing holes (A) and (B) 7.9 mm W16 in) and
plug.
N.B. Ensure bucket is hodzontal before tightening.
16
Page 21
4.3
Slope
5 mm. per metre
1
b) Using support plate as a tempiate mark 2
fixing
*
dots (A).
++q
c) Mark horizontal line through
the
king slots (A) and
-_--_------I
-project to side walk
d) Mark verticaI axis of fIue opening 112 mm (4.4 in) firor
comer of WaIL
300
2
700
:%i
%
Fig.
19
4.4
Fig. 20
J
i M
N
4.5 Water connections
a) Make connecticms to copper tails using either sokier capiIlary fittings or compression type.
4.6 Gas connection
8)
The gas connection is 22 mm diameter.
b)
Make
the gas connection using sokier opiuary Mtings.
N.B. The gas suppIy p’@e must not be less than 22 mm diameter
4.7
Fltthg the boil=
Side outlet flue
1
0 (295 mm minimum)
I
a) Mark vertical csz&e
k-12
for boiler on wall
(see
fig. 20)
e)~wanEr-d~openingo(seetablefig2o)tk
hckm!aIon~wan
f)Driilthewalifortheflueopeningusinga1U7mm(42ir
oxeda
g) DriII 2 Gxing holes (for (H) top of slot)
h)Fksqxrt~towaHuiiq6mxnx5Ommwudszeu
N.B. Ensure sqxxt p&e is horizontal before tightening.
N.B. Dimension (H) decreases as dimension @) i&zases
due
t
therequi&E3llofUueof5mmpermetre
Gas and water
Iahe diametex
conntctions
J) Heatingretum
22mm
L) Gasinlet
22 mm
M) Domestic hot water Bow (optional)
22mm
N) Heating ffow
22mm
a) Copper tails are 22 mm to accept straigh
COXlXXCtOrS.
3 hang boiler on mouting bracket ensure
that it is propeiy located.
b)
connect watex unions
using plain black 3/4- diameter graphited fibre washers. working fKxn left to right.
c) Connect the gas union using the white 3/4 ” 6lter washer (eithe-r Way rOmC0.
N.B. Insert washer into union nut and offer assembly to boiler. Use the plain black 3/4 diameter graphited fibre wash-
for water unions, and gas ensuring that aII connections are tight and sound
.
17
:
Page 22
4.8
4.9
Fitting the safety valve
The safety v&e is mounted below the heating retum U)
(fig. 22) isolating We.
a) Ensure ‘0’ ring is in position within the socket t?om
heating return isolating vaive
bl Fit safetv vaive and secure with grub suew
Drwided.
c) Pit
sup&xt
bracket (A).d) Fit 1% mm taii brain bend
using washer provided.
N.B.
The
drain must be 22 mm and the 14 mm drain
bend from the safety valve must be installed so that
discharge of water is readily visibie. A tundish
anangement is acceptable.
The
cmmedion must NOT be
made by a capilary or compression fitting directly
between the 14 mm drain bend and the 22 mm
discharge pipe without an 2 mm air gap. see fig. 24.
TH8 22
mm DISCHARGE PIPE MUST DISCHARGE TO
m OUTSIDE OF THE BUILDING WEERE POSSIBLE
OVER
A DRAIN. THE DISCHARGE MUST BE
SUCH
THAI IT WILT. NOT BE
HlwmDous TO OCCUPANTS
OR CAUSE DAMAGE TO EXTERNAL ELECTRICAL
COMPONENTS OR
WIRING.
THE PIPE SHOULD BE
DIRECTBD DOWNWARDS. II MUST NOT DISCHARGE
ABOVEAN
ENIRANCEORWINDOWORANYrPPEOF
PUBLIC ACCESS AS THE XEBIFERATURE OF THE
WATER BEING
DISCHARGED MAY REACH 100’ C.
FmtngthclIncop(0700mm108g
a) Cut plastic duct (G) to length
required. see !ig. 2 or
3
dimension
(I).
b)
Cut same amount kom aluminium
flue duct 0.
NB.
In very cold weather the plastic air duct becomes brittle.
waml before cutting.
c) Remove plastic turret cover (D) from ffue turret (B)
held by two screws.
d) Peei off protective paper from adhesive side of cork
gasket (A) place on mating side of flue turret (B) lining
up with four dearance holes, press together.
c) SIide kxking ring (C) and ‘0’ ring over plastic air duct.
0 Siide air duct over tlue duct, engage end of ffue duct
into temGnaI and locate air duct into
turret
(B).
g) Siide ‘0’ ring along air duct Q. to contact with the face
of the turret (B). Locate lugs on locking ring (C)
between iugs on flue turret (B). Push together and
turn to lock.
h) Position square channelled rubber gasket 0 on the
flue hood outlet of the boiler. channel facing
downwards.
t) Pass the fiue assembly through the wali and seat turret
(B). onto the flue outlet, secure with 4 screws
provided.
N-B. The teminai must extend 13 mm (0.5 in) past the
surhe of the external wail (see figs 2 and 3).
f) Pit wali
pIat
(P) provided with mastic seaiing ring over
air duct
to structure.
k) Make good intemaI wall face where the air/flue duct
assembIi2s exit the room.
I) Refit the plastic turret over.
18
Page 23
4.10
Rttfng the flue ows 700 mm long
a) AssembQ is precise@ as dewed in section 4.10 using the requisite number of extension flue and air ducts. Jr,
pdkuIar note the following.
b)
The standard tlue duct is always used at the appliance end (uncut).
C) The standard air duct is always used at the terminal end
(uncut).
d) When cutting, always cut one extension
flue
duct and the same amount from one extension air duct Always cut the
plain end NOT the socket end.
.
c) Full details of dimensions and assembly are given in figs. 2
or
3 as applicable.
1) If internal fktures prevent the assembled ducts beiig passed through the wail kern the inside, the ducts may be
pushed through from outside (remove the locking ring (C) and 0 ring first).
N.B. see also
section
4.3
4.11
4.11.:
Making the electrkal connecffon
( Heating only without 3 ports mid position valve).
N.B. See Section 2.6
for electricaf supply requirements THLS APPLIANCE MUST BE EARTHED.
4Fi?movethe~vews(A)hti~bme:and~cbwn thebo&an~(see~227).unQthethree~0and
lemoxtheeN(o(seefi&27).
b)
Remove plug (A) by pressing the security tay (B) and pulling carefully away (see 27 A).
cl Remove plug cover by undoing the three screws
and puIiing it away from the plug base, cut away for cabIe access as
required.
fig. 23
a) Connect permanent live to L terminal (1). earth to E terminal (2). neutral to N terminal (3).
Make
the earth conductor
of A greater length than the current
carrying conductors so that if the fkx is stmined then the earth would Ix the last
to become disconnected.
c) Remove iink beetween temkals 4 and 5, and connect extemal controls to temGna!s 4,s and 6 (see fig. 27 b) and
section 5.
f) Ensure that the 5ex is located in the able clamp and replace plug cover and relocate and tighten the three screws.
0) Push plug (A) carefully into plug (C) loci&ad on appliance base, making sure that it is fulry home and that the security
tag is engajed.( fig. 27 and 27 A).
h) Ensure that all flexiile cables enter the appGance via the slot and
g
rommets provide in the bottom paneL Reiit (pass
hit) the metaI cover (0 with the king saews (D) and hinge the bottom panel into origid position. Refix the bottom
padwiththescrews
(Al (see 6g.m. --
KEEP CASE AWAY FROM HOT suRFa.
19
Page 24
4.11.;
b)
Remove plug (A) by pressing the security tay (B)and pulling carem away (see 27 A).
c) Remove plug cover by undoing the three screws
and pulling it away from the plug base. cut away for cabIe access as
required.
Fig. 24
d)
CONNECT PER~~NEKT LIVE TO L TERMINAL
(1). ~TH
TO E TERMINN
(2).
NEUTRAL
TO
N TERMINN (3).
h&E THE EARTH
CONDUCIOR OF A GREATER
LENGTH THAN ‘ZHE cURRENT
CARRXNG
coNDKToRs so THAT IF THE Ft5t Is STRAINED
THENTHEEARlH
W~ULDBE'IHELMTTORECO~~EDLXO~
e) Remove link beetween texminak 4 and 5. and conect external controls to tenninais 4.5 and 6 (see tig. 27 b) and
section 5.
f) Ensure that the fIex is located in the cable clamp and replace plug cover and relocate and tighten the three screws.
gI Push plug (A) carefuQ into plug (0 lodaed on appliance base, making sure that it is fiJfy home and that the security
tag
is engajed.( fg. 27 and 27 A).
h) Remove small plug by pressing the sewrity tay (B) and pulling GW&IQ away (see fig27 B).
1) Remove play cover by indowing the two
saewsandpuliingitawaykomtheplaykse.
1) Remove the link between tenninak Tl and R and connect extemal ccmtrok to teamin& Tl, TZ and S3 (see fig. 27 B)
and section.
k) Ensure that the fkxis located in the cabIe clamp and replace plug awer and relocate and tighten the two scrw~.
0 Push plug (D) carefuny into plug (E) kxated in the appliance space making sure that it is fuily home and that the
security tag is engaged.
m) Remove sccket kom the plug on the conductors for the 3 pod We (this is found on rear chassis) connect the plug to
the socket provide on the valve head (see fig. 27 0.
4 Ranove small plug by pressing the security tay (B) and pulling catefuny away (see f&27 B).
20
Page 25
4.12 VERTICALFLUE
Fig. 26
A
+
i
PO&o&g
the boiler (see fig. 25)
a) Select the location for the boiler refering to the
dimensions shown in 1.1 and 1.3.
b)
Sefect the flue configuration (see section 1.44).
c)
Mark vertid centre Iine for boikr on Wan.
cl) Mark horizontal line for top bracket fixing screws.
c) Using bracket as template mark 2 Exing points (I-9.
f) DrilI 2
fixing hdes (HI and plug.
g)
Fii
bracket to
wall
using
6 mm x 50 mm wood screws
provided (see 6g. 25).
Fitting the flue
adaptor
to the boiler (see tig. 26)
a)Peeioffpaedivepaperkxntheadhesivesideoftheaxk
gaskei (A) and phac us the mat@ side of the &re adaptcc
b)FWknthesqwz cWnnekdrubbergasket(aonthe6ue
hoGdout&tofthelxserchannei&ngdownwa&into
tlYzbci!er-
c)SeattheDueadaptorontq3oftheMermaEngsurethat
bothgasketsareinpfaceandsecuretheadaptortothe
bt9erbythe4screwspcov&zLUti&ingthe2ri@hand
sae!wstofixthepesnneswitchsupport(D).
NB:IWngthefbre
The flue tan now be fitted into the adaptor vi3 the reducer.
makingsurethataUsectbnsmetighUysecraedby~
them6dyintopsiticaAUsectimsmustbesupportedt0
ehsurestabGfyarxinoex55sive~putmthebciIer(see
satial1.4.4).
Fig. 26
21
Page 26
Three port mid positton v&e (kit N”100976)
to hit the
1
v&e:
1) Drain the boiler (if applicable (see section
6.2)).
2) Remove the casing (see section 7.1)
3) Remove pressure switch and b ,:ket by
Glrhuy puning it towards.
You disengaging the two spring clips. Carefully.
place the bracket on to the top of the pump.
4) Remove the sealed chamber front pane1 (see
section 7.2)
5) Remove right hand side pane1 by stiding it
airefuuy towards you
6) Remove overheat thermostat (F) by removing
the two fixing screws (Al (see 6g. 29 Al
7) Disconnect and remove the Bow tube Q by
endoing the unions 63) (see 29
A)
8) Fit the new flow tubes (C) and (D) and
connect the port valve (see 6g. 29 B) locate the two &ring
saews (G) into the brass housing at the outlet of tube (D)
(ensure that washes and-are in place and ail joints are
tight
N.B
: IMPORTANT
ensure that the ruber gromet (H) is
located correct&&e 29
B)
9) Refit the overheat thermostat (F)
10) Connect the eiectricai plug (see section 4.13
f@. 27 c)
11) Refill boiler and test for leaks (see section 6.2)
12) Refit sealed chamber panels and relocate
pressure switch bracket (check to see that no damage has
accured or any connections broken.
13) ReEt casing.
I
22
Page 27
Notes
Page 28
ESPOI 7
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