Ultrapower sxi
Installation and Servicing
13121
100sxi
G.C. No. 41-019-09
170sxi
G.C. No. 41-019-10
High Efficiency
System Store
www.glow-worm.co.uk
Guarantee Registration
Thank you for installing a new Glow-worm appliance in your home.
Glow-worm appliances are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive Guarantee.
This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture, whichever is the shorter, for parts. In addition this product is guaranteed for 12 months from the date of installation or 18 months from the date of manufacture, whichever is the shorter, for labour.
The second year of the parts guarantee, from the beginning of the 13th month onwards after installation or manufacture, is conditional upon the boiler having been serviced by a competent person approved at the time by the Health and Safety Executive, in accordance with the manufacturer’s recommendations. We strongly recommend regular servicing of your gas appliance, but where the condition is not met, any chargeable spare parts or components issued within the applicable guarantee period still benefit from a 12 month warranty from the date of issue by the manufacturer.
We recommend you complete and return as soon as possible your guarantee registration card.
If your guarantee registration card is missing you can obtain a copy or record your registration by telephoning the Glow-worm Customer Service number 01773 828100.
In addition Glow-worm offers a guarantee of 10 years for the stainless steel cylinder against faulty materials or manufacture provided that:
The following information is important as without it your guarantee may be invalid.
1.The warranty will become invalid if the damage is due to scaling, frost damage, transient voltages, lightning strikes or any act of vandalism or misuse.
2.The proof of purchase must be produced in the event of any warranty claim (bill of sale).
3.The appliance must be installed by a competent person approved at the time by the Health and Safety Executive, to the prevailing standards, installation book and building regulations at the time of installation.
4.The “Benchmark” Installation, Commissioning and Service Record must be completed on installation and kept up to date.
5.The appliance must be serviced annually.
6.The installation must be in an appropriate location and its use is restricted to potable water (chloride levels less than 200 mg/l).
7.Tampering or modification will invalidate the warranty.
8.The guarantee card must be completed and returned to Glow-worm within 30 days of purchase.
PLEASE NOTE THIS EXTENDED GUARANTEE IS NOT TRANSFERABLE AND RESTS WITH THE ORIGINAL HOUSEHOLDER.
Customer Service: 01773 828300
Technical Helpline: 01773 828100
General and Sales enquiries:
Tel. 01773 824639 Fax: 01773 820569
To register your Glow-worm appliance call: 0800 0732142
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme.
Visit www.centralheating.co.uk for more information.
2
These instructions consist of, Installation, Servicing, Fault Finding, Replacement of Parts and Spares. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety (Installation and Use) Regulations, be handed to the user on completion of the installation.
CONTENTS |
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DESCRIPTION |
SECTION |
PAGE |
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Warnings |
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4 |
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Important Information |
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4 |
INTRODUCTION |
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Statutory Requirements |
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5 |
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Boiler Design |
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6 |
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Safety Devices |
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6 |
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Servicing, Maintenance & Spare Parts |
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6 |
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Boiler Specifications |
1 |
7 |
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Boiler Location, Clearances & Ventilation |
2 |
10 |
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Flue Options and Terminal Clearances |
3 |
11 |
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Heating System |
4 |
13 |
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Domestic Hot Water |
5 |
14 |
INSTALLATION |
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Condensate Drain |
6 |
16 |
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Installation Preparation |
7 |
18 |
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Gas, Water & Boiler Connection |
8 |
20 |
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Condensate & Safety Discharge Valve |
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Connections |
9 |
22 |
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Flue Preparation and Installation |
10 |
23 |
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Electrical Connection |
11 |
37 |
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Commissioning |
12 |
40 |
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Servicing |
13 |
44 |
MAINTENANCE |
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Fault Finding |
14 |
49 |
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Replacement of Parts |
15 |
56 |
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Spare Parts |
16 |
69 |
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Declaration of Conformity |
17 |
71 |
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3
WARNINGS
Gas Leak or Fault
Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e.smoking, blowlamps, hot air guns etc.
Do not operate electrical lights or switches either on or off. Open all doors and windows, ventilate the area.
Metal Parts
This boiler contains metal parts (components) and care should be taken when handling and cleaning, with particular regard to edges.
Sealed Components
Under no circumstances must the User interfere with or adjust sealed parts.
Important Information
Gas Category
This boiler is for use only on G20 natural gas, but may be converted for use on G31 gas (Propane L.P.G.).
Gas Safety (Installation and Use) Regulations
In your own interests and that of safety, it is the Law that ALL gas appliances are installed by competent person approved at the time by the Health and Safety Executive in accordance with the current issue of the above regulations.
Control of Substances Hazardous to Health
Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health.
The adhesives and sealants used in this appliance are cured and give no known hazard in this state.
Insulation Pads / Ceramic Fibre
These can cause irritation to skin, eyes and the respiratory tract.
If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is broken.
Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or going to the lavatory.
If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.
Manual Handling
With regards to the “Manual Handling Operations, 1992 Regulations”, it should be noted that each appliance module exceeds the recommended weight for a one person lift.
The handling of the boiler may involve lifting, pushing and pulling, the use of a sack truck may be required.
The following handling techniques and precautions should be considered:
-Grip the boiler at its base
-Be physically capable
-Use safety clothing where appropriate, e.g. gloves, safety footwear.
Ensure safe lifting techniques are used
-Keep back straight.
-Avoid twisting at the waist.
-Avoid upper body/top heavy bending.
-Always grip using the palm of the hand.
-Use designated hand holds.
-Keep load as close to body as possible.
-Always use assistance if required.
Electrical Supply
The electrical installation must be installed by a competent person approved at the time by the Health and Safety Executive and in accordance with the relevant standards.
The boiler and immersion heater must be earthed.
All system components shall be of an approved type and all wiring to current I.E.E. wiring regulations.
External wiring must be correctly earthed, polarised and in accordance with the relevant standards.
In GB this is BS 6891.
In IE this is the current edition of I.S.813 “Domestic Gas Installations”.
The boiler must be connected to a permanent 230V ac, 50Hz supply.
Connection of the whole electrical system of the boiler, including any heating controls, to the electrical supply must be through one common isolator and must be fused 3 Amp maximum.
Isolation should be by a double pole switched fused spur box, with a minimum gap of 3mm for both poles. The fused spur box should be readily accessible and preferably adjacent to the appliance. It should be identified as to its use.
Alternatively connection can be made through an unswitched shuttered socket and 3A fused 3-pin plug both to the current issue of BS 1363 may be used, provided they are not used in a room containing a bath or shower.
Wiring to the boiler must be PVC 85OC insulated cable, not less than 0.75mm2 (24/0.20mm).
Immersion Heater - a thermostatically controlled immersion heater with manual reset is fitted to the cylinder as a back up for domestic hot water in the event of the boiler being inoperable. The immersion heater MUST be wired separately using 3kW 13amp wiring and in accordance with the relevant standards.
4
Statutory Requirements
Testing and Certification
This boiler is tested and certificated for safety and performance. It is, therefore, important that no alteration is made to the boiler, without permission, in writing, by Glowworm.
Any alteration not approved by Glow-worm, could invalidate the certification, boiler warranty and may also infringe the current issue of the statutory requirements.
CE Mark
This boiler meets the requirements of Statutory Instrument, No. 3083 The Boiler (Efficiency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels.
Type test for purposes of Regulation 5 certified by: Notified body 0087.
Product/production certified by: Notified body 0086. The CE mark on this appliance shows compliance with:
1.Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels.
2.Directive 73/23/EEC on the harmonisation of the Laws of the Member States relating to electrical equipment designed for use within certain voltage limits.
3.Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.
IMPORTANT
Where no British Standards exists, materials and equipment should be fit for their purpose and of suitable quality and workmanship.
The installation of this boiler must be carried out by a competent person approved at the time by the Health and Safety Executive in accordance with the rules in force in the countries of destination.
Manufacturer’s instructions must not be taken as overriding statutory requirements.
Statutory Requirements
Installation of this boiler falls within the scope of the Building Regulations 1995 (Part G). This requires that the installation of an unvented system should be notified to the local authority Building Control Department and that the work must be carried out by a competent person approved at the time by the Health and Safety Executive, as defined in the approved document G3.
In GB, the installation of the boiler must comply with the requirements of the current issue of BS6798 and be carried out by a competent person approved at the time by the Health and Safety Executive, as described in the following regulations:
The manufacturer’s instructions supplied.
The Gas Safety (Installation and Use) Regulations.
The appropriate Buildings Regulations either The Building Regulations, The Building Regulations (Scotland),The Building Regulations (Northern Ireland).
The Water Supply (water fittings) Regulations 1999 and water byelaws 2000, Scotland.
The Health and Safety at Work Act, Control of Substances Hazardous to Health (COSHH).
The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a competent person approved at the time by the Health and Safety Executive and installed in accordance with the current edition of I.S.813 “Domestic Gas Installations”, the current Building Regulations and reference should be made to the current ETCI rules for Electrical Installation.
In GB, the following Codes of Practice apply:
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1, BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593, BS7671.
In IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
NOTE: For further information, see the current issue of the Building Regulations, approved document L1 ( in the UK) and the following current issues of:
1)Central heating system specification (CheSS) and
2)Controls for domestic central heating system and hot water. BRECSU.
Gas Supply
The gas installation must be in accordance with the relevant standards.
In GB this is BS6891.
In IE this is the current edition of I.S.813 “Domestic Gas Installations”.
The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler.
On completion, test the gas installation for soundness using the pressure drop method and suitable leak detection fluid, purge in accordance with the above standard.
Domestic Hot Water
All domestic hot water circuits, connections, fittings must be in accordance with the relevant standards and water supply regulations.
GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide.
IE: The current edition of I.S.813 “Domestic Gas Installations”.
Heating System
In GB, it is necessary to comply with the Water Supply (Water Fittings) Regulations 1999 (for Scotland, the Water Byelaws 2000, Scotland).
To comply with the Water regulations your attention is drawn to: The Water Regulations guide published by the Water Regulations Advisory Service (WRAS) gives full details of the requirements.
In IE, the requirements given in the current edition of I.S.813 “Domestic Gas Installations” and the current Building Regulations must be followed.
5
Boiler Design
Boiler Design
This boiler is designed as a high efficiency central heating appliance, close coupled to an un-vented cylinder. The pumps, expansion vessels and associated safety devices are all fitted within the appliance, providing a one box solution for properties requiring a high domestic hot water demand. The intelligent control system is designed for both simple operation and maximum control. Once the controls are set the boiler will operate automatically.
Additionally a thermostatically controlled immersion heater with manual reset is fitted to the cylinder as a back up for
domestic hot water in the event of the boiler being inoperable. It is intended for use as a back up should the boiler fail, it will not give optimum DHW performance.
Pluming from flue terminal
Like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather. This is due to the high efficiency and hence low flue gas temperature
of the boiler. This is normal and not an indication of a fault.
Condensate Drain
A plastic drain pipe must be fitted to allow discharge of condensate to a drain.
Condensate should, if possible, be discharged into the internal household draining system. If this is not practical, discharge can be made externally into the household drainage system or a purpose designed soak away, see section 6 for more details.
Safety Devices
Electrical Supply Failure
The boiler will not work without an electrical supply.
Normal operation of the boiler should resume when the electrical supply is restored.
Reset any external controls, to resume normal operation of the central heating.
If the boiler does not resume normal operation press the reset button. If the boiler does not resume normal operation after this, refer to fault finding.
Overheating Safety
In the event of the boiler overheating the safety devices will cause a safety shutdown. A “Reset” may be required if a fault code (‘F’ followed by a number) appears on the digital display, refer to ‘F’ codes, section 14 Fault Finding. A manual reset button is also provided on the thermostat in the immersion heater.
Safety Discharge Valves
Three safety discharge valves and discharge pipes are fitted to the boiler, two PRV’s and one pressure/temperature relief valve. The valves must not be touched.
Should there be any discharge from the pipes, isolate the boiler electrical supply and call your installer or Glow-worm’s own service organisation using the telephone number on the inside front cover of this booklet.
Frost protection
The appliance has a built in frost protection device that protects the boiler from freezing. With the gas and electric supplies ON and irrespective of any room thermostat setting, the frost protection device will operate the pump when the temperature of the boiler water falls below 8OC.
After 10 minutes the pump will be stopped if the temperature is higher than 10OC or has already reached 35OC.
The burner will activate if the boiler temperature does not reach 10OC after 30 minutes or at any time if the temperature drops to 5OC.
The burner will switch off when the temperature reaches 35OC.
Frost protection is also built into the cylinder.
Should the cylinder temperature fall below 10OC, the tank is re-heated to a temperature of 15OC.
The cylinder has a built in disinfection cycle which raises the water temperature to 70OC for 1 hour every Wednesday at 2:00am.
Condensate Drain Blockage
As a safety feature the boiler will stop working if the condensate drain becomes blocked. During freezing conditions this may be due to the forming of ice in the condense drain external to the house. Release an ice
blockage by the use of warm cloths on the pipe, the boiler should then restart.
Servicing, Maintenance and Spare Parts
Servicing and Maintenance
To ensure the continued efficient and safe operation of this boiler, it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage.
If this boiler is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety (Installation and Use) Regulations, Section 35.
Servicing/maintenance should be carried out by a competent person approved at the time by the Health and Safety
Executive in accordance with the rules in force in the countries of destination.
Spare Parts
Remember, when replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Glow-worm.
If a part is required contact Glow-worm’s own service organisation.
Please quote the name and model of the boiler.
The name badge is on the front of the appliance and the model type is positioned on the top edge of the tank module front panel.
If in doubt seek advice from the local gas company or Glowworm’s own service organisation using the telephone number on the inside front cover of this booklet.
6
1 Boiler Specifications
Data
All dimensions are given in millimetres (except as noted). See diagram 1.1 and the Boiler Specification Table below.
The data label is positioned inside the boiler module on the base.
13340
7
1 Boiler Specifications
13247
Diagram 1.1
8
1 Boiler Specifications
13290 |
Diagram 1.2 |
9
2 Boiler Location, Clearances and Ventilation
2.1 Location
This boiler is not suitable for outdoor installation.
This boiler may be installed in any room, although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements.
This boiler is suitable for installation in bathroom zones 2 and 3.
In GB this is the current I.E.E. WIRING REGULATIONS and BUILDING REGULATIONS.
In IE reference should be made to the current edition of I.S.813 “Domestic Gas Installations” and the current ETCI rules.
2.2 Clearances
The boiler should be positioned so that at least the minimum operational and servicing clearances are provided, see diagram 2.1.
Additional clearances may be beneficial around the boiler for installation and servicing.
For flue installations where external access is not practicable, consideration should be given for the space required to insert the flue internally, which may necessitate a clearance larger than those specified in diagram 2.1.
2.3 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE/UP/7/1998. If in doubt seek advice from local gas undertaking or Glow-worm.
2.4 Room Ventilation
The boiler is room sealed so a permanent air vent is not required.
2.5 Cupboard or Compartment Ventilation
Due to the high efficiency and hence low casing temperature of this boiler, cupboard or compartment ventilation is not necessary.
Leave existing air vents.
13241 |
Diagram 2.1 |
10
3 Flue Options and Terminal Clearances
HORIZONTAL FLUES
ADIRECTLY BELOW AN OPENING, AIR BRICK,
OPENING WINDOWS |
300 |
BABOVE AN OPENING, AIR BRICK,
OPENING WINDOWS |
300 |
CHORIZONTALLY TO AN OPENING,
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AIR BRICK, OPENING WINDOWS |
300 |
D |
BELOW GUTTER, DRAIN/SOIL PIPE |
25 |
E |
BELOW EAVES |
25 |
F |
BELOW A BALCONY OR CAR PORT |
25 |
GFROM VERTICAL DRAIN PIPES AND
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SOIL PIPES |
25 |
H |
FROM INTERNAL/EXTERNAL CORNERS |
25 |
H* |
TO A BOUNDARY ALONGSIDE THE |
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TERMINAL |
300 |
I |
ABOVE ADJACENT GROUND OR |
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J* |
BALCONY LEVEL |
300 |
FROM SURFACE OR A BOUNDARY |
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FACING THE TERMINAL |
600 |
K |
FACING TERMINALS |
1200 |
LFROM OPENING (DOOR/WINDOW)
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IN CAR PORT INTO DWELLING |
1200 |
M |
VERTICAL FROM A TERMINAL |
1500 |
N |
HORIZONTALLY FROM A TERMINAL |
300 |
VERTICAL FLUES
P |
FROM ANOTHER TERMINAL |
600 |
Q |
ABOVE ROOF LEVEL |
300 |
R |
FROM ADJACENT OPENING WINDOW |
1000 |
S |
FROM ADJACENT WALL TO FLUE |
300 |
Diagram 3.1
3.1 Flue Options
There are various flue options to choose from as illustrated in diagram 3.3. The flue lengths and installation of various flue types are described in section 10.
3.2 Flue Terminal Position
The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 4.2. In IE the minimum distances for flue terminal positioning must be those detailed in I.S.813 “Domestic Gas Installations”.
The terminal must be exposed to the external air, allowing free passage of air across it at all times.
Being a condensing boiler some pluming may occur from the flue outlet. This should be taken into consideration when selecting the position for the terminal.
NOTE: If necessary it is permitted to increase the terminal protrusion through the outside wall to greater than the minimum dimension of 87mm but no more than 600mm. Carports or similar extensions of a roof only, or a roof and one wall, require special consideration with respect to any openings, doors, vents or windows under the roof. Care is required to protect the roof if made of plastic sheeting. If the carport comprises of a roof and two or more walls, seek
advice from the local gas supply company before installing the boiler.
H* and J* See diagram 4.2 . These dimensions comply with the building regulations, but they may need to be increased to avoid wall staining and nuisance from pluming depending on site conditions.
NOTE: If the flue terminal is positioned near a light source insects may enter the flue system. Where safe and practical to do so advise the homeowner to check the flue outlet and clear visible insects from the terminal end.
Plume Management Kit: Part No.A2044100 (white) or A2044000 (black) can be used to overcome many site issues.
3.3 Terminal Guard
A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage.
If a terminal guard is required, it must be positioned to provide minimum of 50mm clearance from any part of the terminal and be central over the terminal.
The guard should be similar to that shown in diagram 3.2. A suitable guard is manufactured by: -
Tower Flue Components Morley Rd.
Tonbridge Kent TN9 1RA.
Size: 280mm x 165mm. Part No. CGDK3
15583
Diagram 3.2
11
3 Flue Options and Terminal Clearances
14845
Ridge Tile Terminal
Part No. A2043800 -
Section 10, page 32
Top horizontal telescopic flue Ø60/100 |
Top horizontal standard flue Ø60/100 |
- page 23 Part No. A2043600 |
- page 27 Part No. A2043400 |
Vertical Flue - page 31 Vertical Flue Adapter, concentric
flue Ø60/100 Part. No. A2024600
Vertical flue terminal kit, concentric flue Ø60/100 Part. No. 2000460480
Twin Flue - page 34 Twin Flue Adapter, concentric flue Ø80 Part No. A2011000
Plume Management Kit -
page 37 Basic set, concentric flue Ø60/100 White - Part No. A2044100 Black - Part No.
A2044000 for use with Part No. A2043400 and Part No. A2043600
Diagram 3.3
12
4 Heating System
General
The boiler is for use only with sealed central heating systems.
The digital readout on the controls fascia indicates the system pressure when there is no demand.
The circulation pump is integral with the boiler.
4.1 Safety Valves
The safety valves are factory fitted and are an integral part of the boiler and must not be adjusted or used for any other purpose.
NOTE: The pipe from the safety discharge valve must not discharge above an entrance, window or any type of public access area.
4.2 Expansion Vessel
The boiler has an integral expansion vessel with a capacity of 10 litres (2.2 gallons), with a charge pressure of 0.75bar.
NOTE: The expansion vessel volume depends on the total water system volume and the initial system design pressure. Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1, for IE refer to the current edition of I.S.813 “Domestic Gas Installations”.
4.3 Flow Rate
If it is necessary to alter the flow rate, the system can be fitted with a lockable balancing valve in the main flow or return pipes shown as valve “A” in diagram 4.1.
The flow rate through the boiler must not be allowed to fall below that given in section 1 - Specification table.
4.4 Bypass
The boiler is fitted with an automatic adjustable bypass.
Diagram 4.2 shows the pump head remaining for the heating system depending on the bypass setting and the speed setting of the pump, see section 12 Commissioning.
4.5 Filling the Sealed System
NOTE: The water pressure at the boiler must be at least 0.7bar to enable filling the boiler to a minimum pressure through the integral filling device, see diagrams 4.1 and 12.2.
4.6 Water Treatment
In the case of an existing system, it is ESSENTIAL that prior to installing the new boiler the system is thoroughly flushed. For optimum performance after installation of a new system, the boiler and its associated central heating system should also be flushed. Flushing should be carried out in accordance with BS7593: 2006 using a cleanser such as Sentinel X300 or X400, Fernox Restorer or Salamander corrosion guard cleaner.
For long-term corrosion protection, after flushing, an inhibitor suitable for stainless steel exchangers should be used, refer to the current issue of BS 5449 and BS 7593 on the use of inhibitors in central heating systems. Examples are Sentinel X100 Fernox Protector or Salamander corrosion guard inhibitor.
4.7 ‘Hard’ Water Areas
The temperatures within the heat exchanger are limited by the boiler control system to minimise scale formation within the hot water pipework. However, in areas where the water is ‘hard’ (i.e. more than 200mg/litre), it is recommended that the hot water setting is reduced and that a scale reducer is fitted, refer to the manufacturer’s instructions or consult the local water company for additional advice.
13352
Diagram 4.1
13
4 Heating System
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14033 |
capacity |
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4 |
automatic bypass - closed |
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3 |
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conveyancing |
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automatic bypass - factory setting |
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(mH2O) |
2 |
automatic bypass - open |
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Remaining |
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1 |
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pump speed 1 |
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pump speed 2 |
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0 |
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0 |
200 |
400 |
600 |
800 |
1000 |
1200 |
1400 |
1600 |
1800 |
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Volumeflow (Litres/hr) |
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Diagram 4.2
5 Domestic Hot Water
General
All domestic hot water circuits, connections, fittings must be in accordance with the relevant standards and water supply regulations.
The boilers are suitable for connection to most types of domestic appliances.
When connecting to suitable showers, ensure that:
a)The cold water inlet to the boiler is fitted with an approved anti-vacuum or siphon non-return valve.
b)Hot and cold water supplies to the shower are of equal pressure.
5.4 Safety Valves
The safety valves are factory fitted and are an integral part of this boiler and they must not be adjusted or used for any other purpose.
NOTE: The pipe from the safety discharge valve must not discharge above an entrance, window or any type of public access area.
5.1 Water Pressure
This boiler will operate satisfactorily at low water inlet pressure, however for optimum performance it is recommended that 22mm feed pipe is used with an inlet pressure, at the appliance, of 2 bar.
NOTE: Higher pressure can be tolerated as the boiler is fitted with a pressure reducing valve set at 3.5 bar.
5.2 Expansion Vessel
The boiler has an integral expansion vessel with a capacity of 12 litres (2.6 gallons), with a charge pressure of 3 bar.
NOTE: The expansion vessel volume depends on the total water system volume and the initial system design pressure. Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1, for IE refer to the current edition of I.S.813 “Domestic Gas Installations”.
5.3 Draining Point
A draining point is provided at the bottom of the hot water storage tank located next to the condensate drain, see diagram 5.1.
13308
CONDENSE TRAP 
AND
SIPHONIC DRAIN
DRAIN
POINT SCREW
Diagram 5.1
14
5 Domestic Hot Water
5.5 SYSTEM REQUIREMENTS – Domestic Hot
Water
Domestic Hot Water Requirements
NOTE: Attention is drawn to the following extracts from the Building Regulations 1991.
Regulation 11(1) (Giving of a building notice or deposit of plans)
“Subject to the following provisions of this regulation, a person who intends to carry out building work or to make a material change of use shall:
a)Give to the local authority* a building notice in accordance with 12; or
b)Deposit full plans with the local authority* In accordance with regulation 13”.
Regulation 12(4) (Particulars and plans where a building notice is given)
“………a building notice shall be accompanied by a statement which specifies:
*Attention is drawn to regulation 18 (supervision of building work otherwise than by local authorities).
a)The name, make, model and type of hot water storage system to be installed;
b)The name of the body, if any, which has approved or certified that the system is capable of performing in a way which satisfies the requirements of paragraph G3 of Schedule 1;
c)The name of the body, if any, which has issued any current registered operative identity card to the installer or proposed installer of system.”
Regulation 13(3) (Full plans)
“Full plans shall consist of:
a) Description of the proposed building work or material change of use, and the plans, particulars and statements required by paragraphs (1) to (4) of regulation 12: and …….”
NOTE:
Bye-laws of the appropriate Water Undertake also apply.
Discharge Pipework
It is a requirement of Building Regulation G3 that any discharge from an unvented system is conveyed to where it is visible but will not cause danger to persons in or about the building. The tundish and discharge pipes should be fitted in accordance with requirements and guidance notes of Building Regulation G3. The G3 Requirements and Guidance section 3.9 are reproduced in the following sections. Information Sheet No. 33 available from the British Board of agreement gives further advice on discharge pipe installation. For discharge pipe arrangements not covered by G3 Guidance or BBA info sheet no. 33 advice should be sought from your local Building Control Officer.
G3 Requirement
“….there shall be precautions….. to ensure that the hot water discharged from safety devices is safely conveyed to where it is visible but will not cause danger to persons in or about the building”.
G3 Guidance SECTION 3.9
The discharge pipe (D1)from the vessel up to and including the tundish is generally supplied by the manufacturer of the hot water storage system. Where otherwise, the installation should include the discharge pipe(s) (D1) from the safety device(s). In either case the tundish should be vertical, located in the same space as the unvented hot water storage system and be fitted as close as possible and within 500mm of the safety device e.g. the temperature relief valve.
NOTE: The tundishes are factory fitted during manufacture. The discharge pipe (D2) from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge, preferably be of metal and:
a)Be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of straight pipe 9m long i.e. discharge pipes between 9m and 18m equivalent resistance length should be at least two sizes larger than the nominal outlet size of the safety device, between 18 and 27m at least 3 sizes larger and so on. Bends must be taken into account in calculating the flow resistance.
An alternative approach for sizing discharger pipes would be to follow BS67100:1987 specification for design installation, testing and maintenance of services supplying water for domestic use within buildings and their curtilages. Appendix E section E2 and table 21.
b)Have a vertical section of at least 300mm long, below the tundish before any elbows or bends in the pipework.
c)Be installed with a continuous fall.
d)Have discharges visible at both the tundish and the
final point of discharge but where this is not possible or is practically difficult there should be clear visibility at one or other of these locations. Examples of acceptable discharge arrangements are:
i)Ideally below a fixed grating and above the water seal in a trapped gully.
ii)Downward discharges at low level; i.e. up to 100mm above external surfaces such as car parks, hard standings, grassed areas etc. are acceptable providing that where children may play or otherwise come into contact with discharges a wire cage or similar guard is positioned to prevent contact whilst maintaining visibility.
iiI) Discharges at high level; e.g. into a metal hopper and metal down pipe with the end of the discharge pipe clearly visible (tundish visible or not) or onto a roof capable of withstanding high temperature discharges of water and 3m from any plastic guttering system that would collect such discharges (tundish visible).
iv)Where a single pipe serves a number of discharges, such as in blocks of flats, the number served should be limited to not more than 6 systems so that any installation discharging can be traced reasonably easily. The single common discharge pipe should be at least one pipe size larger than the largest individual discharge pipe (D2) to be connected. If unvented hot water storage systems are installed where discharges from safety devices may not be
apparent i.e. in dwellings occupied by blind, infirm or disabled people, consideration should be given to the installation of an electronically operated device to warn when discharge takes place.
15
5 Domestic Hot Water
NOTE: The discharge will consist of scalding water and steam. Asphalt, roofing felt and non-metallic rain water goods may be damaged by such discharges.
Worked example of discharge pipe sizing
The example given in diagram 5.2 is for a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No. 22mm elbows and length of 7m from the tundish to the point of discharge.
From Table 1:
Maximum resistance allowed for a straight length of 22mm copper discharge pipe (D2) from a G1/2 temperature relief valve is 9.0m.
Subtract the resistance for 4 No. 22mm elbows at 0.8m each = 3.2m.
Therefore the permitted length equates to 5.8m.
5.8m is less than the actual length of 7m therefore calculate the next largest size. Maximum resistance allowed for a straight length of 28mm pipe (D2 from a G1/2 temperature relief valves equates to 18m. Subtract the resistance of 4 No. 28mm elbows at 1.0m each: 4.0m.
Therefore the maximum permitted length equates to: 14m. As the actual length is 7m a 28mm min (D2) copper pipe will be satisfactory.
WARNING:
• Under no circumstances should the factory fitted temperature/pressure relief valve be removed other than by authorised personnel. To do so will invalidate any
warranty claim.
•Table 1. Sizing of copper discharge pipe (D2).
•Control and safety valves MUST NOT be tampered with.
•The discharge pipe MUST NOT be blocked or used for any other purpose.
•The tundish is factory fitted and MUST NOT be removed.
TABLE 1 |
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13449 |
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Valve outlet |
G 1/2 |
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size |
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Discharge pipe D1 |
15mm |
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Discharge pipe D2 from |
22mm |
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tundish |
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Maximum resistance allowed, |
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expressed |
up to 9m |
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as a length of straight |
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pipe (i.e. no elbow or bends) |
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Resistance created by |
0.8m |
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each elbow or bend |
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12529 |
Diagram 5.2 |
6 Condensate Drain
6.1 Condensate Drain
A plastic drain pipe must be fitted to allow discharge of condensate to a drain.
Condensate should, if possible, be discharged into the internal household draining system. If this is not practical, discharge can be made externally into the household drainage system or a purpose designed soak away, see diagram 6.1 for more details.
6.2 Condensate Connection
A flexible condensate connection pipe is supplied and should be used to connect to a drain outlet pipe 22mm to 25mm OD. non corrosive plastic . The drain outlet pipe should have a fall of at least 2.50 away from the boiler.
It is recommended that any external condensate drain pipe is insulated and also preferably of 32mm diameter, to prevent freezing in adverse weather conditions.
The condensate is discharged periodically in ‘slugs’ by siphonic action.
It is not necessary to provide air breaks or extra traps in the discharge pipe as there is already a trap inside the boiler. Fitting an extra trap may cause the boiler siphon to work incorrectly.
16
6 Condensate Drain
INTERNAL SOIL |
BOILER |
AND VENT STACK |
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DIA. 22mm MIN.
NO RESTRICTION
ON LENGTH
Internal Soil and Vent Pipe
EXTERNAL SOIL |
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BOILER |
13443 |
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AND VENT STACK |
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EXTERNAL |
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MAX. 3M |
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DIA. 22mm MIN. |
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NO RESTRICTION |
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ON LENGTH |
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External Soil and Vent Pipe or Rainwater Pipe
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BOILER |
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EXTERNAL LENGTH |
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OF PIPE 3M MAX.* |
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DIA. 22mm MIN. |
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OPEN END OF PIPE |
*NOTE: FOR EXTENDED |
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DIRECT INTO GULLEY |
PIPE RUNS 32mm DIA. |
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BELOW GROUND BUT |
PIPE SHOULD BE USED. |
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ABOVE WATER LEVEL |
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BOILER
SINK (CONSTITUTES AIR BREAK)
DIA. 22mm MIN.
NO RESTRICTION
ON LENGTH
Internal Termination into Combined Sink Waste
External Termination to a Gulley or Hopper |
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3M MAX. |
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DIA. 22mm MIN. |
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DIA. 22mm MIN. |
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TERMINATION FROM APPLIANCE. |
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GROUND |
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NO RESTRICTION |
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ON LENGTH |
BOILER |
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(either/or) |
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500mm MIN. |
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SINK |
SEAL |
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25mm MIN. |
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DIA. 100mm |
300mm |
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PLASTIC TUBE |
MIN. |
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BOTTOM OF |
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OPEN END OF PIPE DIRECT INTO |
TUBE SEALED |
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LIMESTONE CHIPPINGS |
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GULLEY BELOW GROUND LEVEL |
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BUT ABOVE WATER LEVEL. |
HOLE DEPTH |
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400mm MIN. |
2 ROWS OF 3 x 12mm HOLES AT |
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25mm CENTRES 50mm FROM |
Internal Termination Downstream of |
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FACE AWAY FROM HOUSE. |
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Sink Waste |
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External Termination into Soakaway |
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NOTE: PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2.5 o 44mm FOR EVERY 1M.
17
7 Installation Preparation
13405
PLUMBING JIG
TANK / BOILER MODULE CONNECTION WASHERS
13248
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J |
H |
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H |
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M |
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H |
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Retaining screws |
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TANK / JIG |
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C |
stored in cartridge |
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CONNECTION WASHERS |
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LOOSE ITEMS PACK |
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A |
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Installation booklet (not illustrated) |
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1 OFF |
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User Instructions (not illustrated) |
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1 OFF |
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Condensate Connection Pipe |
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1 OFF |
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D |
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22mm Copper Tails |
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4 OFF |
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15mm Copper Tail |
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1 OFF |
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3/4" Sealing Washer (white plastic) |
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4 OFF |
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1/2" Sealing Washer |
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2 OFF |
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3/4" Sealing Washer (beige) |
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5 OFF |
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Pump Washer |
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1 OFF |
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K |
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Floor Template |
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1 OFF |
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Electrical Cartridge |
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1 OFF |
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Cartridge Screws (stored in cartridge) |
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2 OFF |
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3/4" Sealing Washer (blue) |
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4 OFF |
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Diagram 7.1
18
7 Installation Preparation
7.1 Loose Items Pack
Please check the contents of loose items pack as shown in diagram 7.1.
The plumbing jig is located within the tank module polystyrene top pack.
7.2 Site Requirements
The appliance should be sited on a level floor, however slight adjustment can be made using the adjustable feet at the base of the tank module.
The floor strength should be suitable for the combined weight of appliance and water:
100sxi 175kg 170sxi 225kg
NOTE: Due to the varied site conditions we do not supply fixings and advise that the installer should supply those which are suitable.
7.3 Floor Template
Take the floor template from the loose items pack and place in the desired position on the floor, giving due consideration to the required boiler clearances, see diagram 2.1, and the flue you are fitting.
Mark the position of the flue centre, if fitting a side flue, extend the flue centerline into the corner then along the adjacent wall, see diagram 7.2.
For extended side flues, the flue hole centre should be determined by extending the dashed inclined line on the template to the side wall. This dashed line is drawn at 44mm/ metre (2.5°) rise from the boiler. Where this line reaches the side wall, a horizontal line should be marked. The vertical centre line of the flue should then be marked on the back wall.
To allow for the flue passing through the wall at this angle a 125mm hole should be drilled irrespective of internal or external installation.
7.4 Flue Hole Cutting
External access flue installation can use a 105mm diameter core drill.
Internal access only flue installation will need a 125mm diameter core drill.
NOTE: The flue is designed with an internal fall of 44mm/ metre (2.5°), therefore the hole can be drilled horizontally.
If flue extension pipes are to be used then a core drill size of 125mm is required. This will allow the extension pieces to slope at 44mm/metre (2.5°) towards the boiler.
7.5 Plumbing Jig
Align the template with the flue hole then mark the position of the fixing holes for the jig, see diagram 7.3.
Align the location notches on the jig and secure to the floor using suitable screws.
2 |
1 |
/ |
o |
(44mm/metre) FALL TOWARDS THE BOILER IS |
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REQUIRED WHEN FLUE EXTENSIONS ARE USED |
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13418 |
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1331 |
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(100sxi) |
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1591 |
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(170sxi) |
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TEMPLATE |
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Diagram 7.2 |
13376 |
Diagram 7.3 |
19
8 Gas, Water & Boiler Connection
8.1 Systems Connection
The water and gas isolation valve connections are on the jig.
The condense drain and safety discharges connections are not on the jig but their pipe runs are shown on the template.
Assemble the copper tails and washers to the jig, secure, then plumb the system as shown in diagram 8.1. taking into account the need to plumb the condense and safety valves also.
NOTE: Do not subject isolation valves to heat.
Slacken the test point screw, see diagram 8.1, connect a manometer.
The whole of the gas installation, including the meter, should be inspected, tested for tightness and purged in accordance with the current issue of BS6891 and in IE the current edition of I.S.813 “Domestic Gas Installations”.
Remove the manometer and secure the test point screw.
On completion of system connections and as an aid to installation, slacken the jig securing screws, this will allow a greater tolerance of site conditions when connecting the isolation valves to the boiler.
IMPORTANT: With regards to the Health and Safety Manual Handling requirements, two persons shall be required to lift the appliance. It should be noted that the appliance is made up of two modules each module requiring two persons to lift.
8.2 Tank Module Connection
IMPORTANT: The electrical cables to the boiler and the immersion heater need to be routed before the installation of the tank module.
Remove the tank module top polystyrene packing, then the carton sleeve.
Pull the tank module front panel forward off the retaining clips.
Slide the tank module into position over the jig and align with the isolation valves.
NOTE: If there is restricted clearance where the boiler is to be located, the tank and boiler modules can be assembled before sliding into position over the jig.
Position the plastic sealing washers as shown in diagram 8.3 and connect the isolation valves. The pipe retaining bracket can be slackened to ease connection.
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PIPE WORK |
68/78 |
ROUTING |
(IF REQUIRED) |
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ADJUSTABLE FEET |
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VIEW SHOWING
SIDE OUTLET PIPE WORK ROUTING AT BACK OF BOILER (IF REQUIRED)
15mm COPPER TAIL
22mm COPPER TAIL
13402
SEALING |
SEALING |
WASHER |
WASHER |
GAS ISOLATION VALVE |
ISOLATION VALVE (typical) |
CONDENSATE |
DHW SAFETY |
DRAIN |
RELIEF |
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VALVE |
CH SAFETY |
DISCHARGE |
RELIEF |
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VALVE |
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DISCHARGE |
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CENTRAL |
DHW |
GAS |
GAS INLET |
DHW |
CENTRAL |
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PRESSURE |
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HEATING |
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INLET |
HEATING |
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OUTLET |
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TEST POINT |
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FLOW |
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VALVES SHOWN CLOSED |
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RETURN |
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Diagram 8.1 |
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20
8 Gas, Water & Boiler Connection
13416 |
BOILER MODULE |
FRONT PANEL |
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TANK |
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THERMISTOR |
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CABLE |
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FLEXIBLE |
SECURING |
CONDENSATE |
SCREW (2 OFF) |
HOSE CONNECTION |
Diagram 8.2 |
8.3 Boiler Module Connection
Unpack the boiler module from its carton.
Position the boiler on top of the tank ensuring the correct engagement of the locating pins, see diagram 8.3.
Remove the front panel securing screws and lift the panel off at the top locating bracket, see diagram 8.2.
Position the plastic sealing washers as shown in diagram 8.3 and secure to the pipes to the connectors beneath the boiler as shown in diagram 8.2.
On completion secure the pipe retaining bracket if previously slackened and level the boiler using the adjustable feet.
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13415 |
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BOILER MODULE |
SEALING WASHER (beige) |
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(5 OFF) |
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PUMP WASHER |
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LOCATING |
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PIN (4 OFF) |
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TANK MODULE |
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PIPE |
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RETAINING |
SEALING WASHER |
BRACKET |
1/2" |
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SEALING WASHER |
PLASTIC WASHERS |
(white plastic) (4 OFF) |
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FLOOR FIXING JIG |
ADJUSTABLE |
Diagram 8.3 |
FEET |
21
9 Condensate & Safety Discharge Valve Connections
9.1 Safety Discharge Valve
The pipes must be extended, using not less than 22mm o.d. pipe, to discharge, in a visible position, outside the building, facing downwards, preferably over a drain.
The pipe must have a continuous fall and be routed to a position so that any discharge of water, possibly boiling, or steam cannot create any danger to persons, damage to property or external electrical components and wiring.
It is advisable to use a 22mm compression elbow to aid in future servicing, see diagram 9.1.
9.2 Condensate Drain Connection
A flexible condensate hose runs from a push-fit connection at the bottom of the heat exchanger and terminates on the boiler module base plate, see diagram 8.2.
Connect the flexible condensate hose to the boiler module, see diagram 9.2.
A flexible condensate connection pipe is supplied in the loose items pack and should be fitted between the condense trap and siphonic drain to the condensate drain pipe, see diagram 9.3, and refer to section 6 to discharge condensate to a drain. The drain pipe 22mm to 25mm OD. non corrosive plastic pipe should have a fall of at least 2.50 away from the boiler.
13463
CH SAFETY RELIEF VALVE |
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DISCHARGE CONNECTION |
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22mm compression |
DHW SAFETY RELIEF VALVE |
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(not supplied) |
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DISCHARGE CONNECTION |
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is the preferred method of |
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connection for servicing. |
Diagram 9.1 |
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13458 |
FLEXIBLE CONDENSATE |
HOSE CONNECTION TO |
BOILER MODULE |
FLEXIBLE |
CONDENSATE |
HOSE |
Diagram 9.2 |
22 |
13312 |
FLEXIBLE |
CONDENSATE |
HOSE |
CONDENSE TRAP |
& SIPHONIC DRAIN |
FLEXIBLE |
CONDENSATE |
CONNECTION |
PIPE |
Diagram 9.3 |
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