Response: The combi boiler
The Ideal Response is a wall mounted, fanned flue combination boiler which
serves a home's central heating system and delivers hot water on demand.
It has been designed to be 'friendly' to the user, installer and service engineer.
Response: The fit anywhere combi
Simple fanned 'go anywhere' flue
The Response's flue turret simply rotates through 360° to allow horizontal
outlet in any direction. Options include horizontal flue length extensions
and the flue is self-sealing, eliminating the need for outside assembly - an
important benefit in high-rise applications.
Downward or upward connections...
Water and gas connections have been designed to be as simple and fast
as possible. The Ideal Response comes complete with a rugged mounting
frame which can accommodate downward or upward routed gas, water and
electrical connections before the boiler is fitted.
...and it fits inside a cupboard
Its compact size - up to half that of other combis - makes the Response
ideal for any kitchen. It can be installed inside a standard size kitchen wall
unit without insulation and with minimal ventilation.
Response: The combi you can rely on
The Response has been designed and developed with reliability as the
number one priority. But even the finest engineered product may develop a
fault at some stage in its lifetime. To support the Response we've created
the Ideal Care Guarantee which sets out our target to repair any fault next
day.
Free Guarantee: 1st Y ear Ideal Care
The home owner is entitled to 12 months free Ideal Care, which includes
both parts and labour, to restore the boiler to full function. Please encourage
the home owner to complete and return the registration form in their
Householder's pack within 30 days of installation.
Optional Extra Y ear Cover with Ideal Care
You may wish to offer your own annual service plan or you may wish to
advise the home owner to complete their application form for the appropriate
level of extended Ideal Care - Silver, Gold or Platinum. Full details are available
in the Ideal Care brochure.
CAUTION.
appliance, care should be taken when handling edges of sheet steel components.
T o avoid the possibility of injury during the installation, servicing or cleaning of this
2
Response 80 / 100 / 120
- Installation
PERFORMANCE DATA
IMPORTANT.
This manual is applicable only to Response boilers with a data plate prefix of RF or above
Table 1 - General Data
Gas supply type & connection 2H-G20-20mbar, 22mm copper
Inlet connection Domestic Hot Water 15mm copper
Outlet connection Domestic Hot Water 15mm copper
Flow & return connection Central heating 22 mm - 28mm copper
Flue terminal diameter mm (in.) 100 (4)
2
Max. working pressure (sealed systems) bar (lb/in
) 2.65 (38.5)
Electrical supply & loading 230 V ~ 50 Hz, 160W max
External fuse rating 3A
Internal fuse rating (BS 42 65) PCB40 F1: 4ATASG PCB40 F2: 2AF HRC PCB41 F1: 2A HRC
Boiler size Height mm (in.) 640 (25 3/16)
Width mm (in.) 436 (17 1/8)
Depth mm (in.) 278 (10 15/16)
Response 80 Response 100 Response 120
o
Average flue temp / mass flow rate 235
C / 11.8 g/s 235 oC / 14.7 g/s 235 oC / 14.7 g/s
Max. DHW water inlet pressure bar (lb/in2) 10.0 (145.0) 10.0 (145.0) 10.0 (145.0)
Min.
DHW water inlet pressure bar (lb/in2) 1.0 (14) 1.2 (17) 1.2 (17)
Dry lift weight kg (lb.) 50 (110) 51.2 (112) 51.2 (112)
Water content Central heating litre (gal.) 1.7 (0.37) 1.7 (0.37) 1.7 (0.37)
Domestic hot water litre (gal.) 0.48 (0.11) 0.7 (0.15) 0.7 (0.15)
Table 2 - Performance Data - CENTRAL HEATING
Max Min Max Min Max Min
Burner pressure (hot) mbar (in.w.g.) 7.2(3.1) 3.5 (1.5) 6.7 (2.6) 1.8 (0.7) 6.7 (2.6) 1.8 (0.7)
Input based on nett CV kW (Btu/h) 19.8
Input based on gross CV kW (Btu/h) 22
Output kW (Btu/h) 17.6
(67500)
(75000)
(60000)
Gas consumption (hot) l/s (ft3/h) 0.568
(72)
12.6
13.9
11.7
0.359
(43000)
(47500)
(40000)
(45)
26.4
29.3
23.4
0.757
(90000)
(100000)
(80000)
(95)
13.2
14.7
11.7
0.380
(45000)
(50000)
(40000)
(48)
26.4
29.3
23.4
0.757
(90000)
(100000)
(80000)
(95.4)
13.2
14.7
11.7
0.380
(45000)
(50000)
(40000)
Table 3 - Performance Data - DOMESTIC HOT WATER
Maximum
Response 80 Response 100 Response 120
Burner pressure (hot) mbar (in.w.g.) 13.2 (5.2) 10.2 (4.0) 13.2 (5.2)
Input based on nett CV kW (Btu/h) 26.4 (90 000) 33 (112 500) 39.7 (135 100)
Input based on gross CV kW (Btu/h) 29.3 (100 000) 36.7 (125 000) 44.0 (150 000)
Output kW (Btu/h) 23.4 (80 000) 29.3 (100 000) 35.2 (120 000)
3
Gas consumption (Hot) l/s (ft
o
Flow 35
C. temp. rise l/m (gpm) 9.6 (2.1) 12.0 (2.6) 14.4 (3.2)
/h) 0.757 (95) 0.95 (120) 1.14 (143)
Domestic hot water specific rate l/m (gpm) 11.2 (2.4) 14.6 (3.2) 17.1 (3.8)
Seasonal efficiency (SEDBUK) * [79.4]% [80.0]% [80.0]%
* The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings.
The test data from which it has been calculated have been certified by notified body.
(48)
Note.
Gas consumption is calculated using a
calorific value of 38.7 MJ/m3 (1038 Btu/ft3) gross or
34.9 MJ/m3 (935 Btu/ft3) nett
To obtain the gas consumption at a different
calorific value:-
a. FOR L/S - divide the gross heat input (kW) by
the gross C.V. of the gas (MJ/m
3
b. FOR FT
/H - divide the gross heat input (Btu/h)
3
)
by the gross C.V. of the gas (Btu/ft3)
Response 80 / 100 / 120
- Installation
Key to symbols
IE = Ireland GB =United Kingdom (Countries of destination)
PMS = Maximum operating pressure of water
C13,C33 = A room sealed appliance designed for connection via ducts
to a horizontal or vertical terminal which admits fresh air to the
burner and discharges the products of combustion to the outside
through orifices which, in this case, are concentric. The fan is up
stream of the combustion chamber.
= An appliance designed for use on 2nd Family gas, Group H only.
I
2H
3
Response 80 (Natural gas) G.C. Appliance No. ........ 47 348 02 B.G. Certified - P.I. No. ........ 87 AS 93
Response 100 (Natural gas) G.C. Appliance No. ........ 47 348 04 B.G. Certified - P.I. No. ........ 87 AT 20
Response 120 (Natural gas) G.C. Appliance No. ........ 47 348 01 B.G. Certified - P.I. No. ........ 87 AS 94
Destination Countries: GB and IE.
Data badge: top RH controls channel
CONTENTS
Air Supply ....................................................................... 7
Boiler Dimensions/Clearances..................................... 6
Boiler Exploded Diagram ............................................ 12
Commissioning and Testing ....................................... 30
Electrical Connections ................................................ 28
Electrical Diagrams..................................................... 28
Electrical Supply Requirements ................................... 9
Extension Ducts - Fitting ............................................. 25
Fault Finding ................................................................. 49
Flow Wiring Diagram ................................................... 28
Flue Fitting
Rear outlet .............................................................. 15
Side outlet .............................................................. 20
INTRODUCTION
Response combi boilers are wall mounted, low water content,
fanned flue combination gas boilers of type C13 intended for use
with gas group I2
Central heating (CH) output modulates between 11.7 kW (40,000
Btu/h) minimum and 23.4 kW (80,000 Btu/h) maximum for
Response 100/120 and 17.6kW (60 000Btu/h) maximum for
Response 80.
Domestic hot water (DHW) output is also fully modulating, with a
maximum of:
Response 80 23.4 kW (80,000 Btu/h)
Response 100 29.3 kW (100,000 Btu/h)
Response 120 35.2 kW (120,000 Btu/h).
The boiler is suitable for connection to fully pumped, pressurised
sealed water systems ONLY.
A system bypass is only required when TRV's are fitted to all
radiators (see Frame 5).
Boilers are supplied fully assembled and, being a 'tube-withintube' design, require no diverter valve or domestic hot water calorifier.
A circulating pump, pressure gauge, safety valve and expansion
vessels for both central heating (CH) and domestic hot water (DHW)
are provided.
H.
Flue Installation Requirements..................................... 8
Gas Safety Regulations................................................. 7
Gas Supply Requirements ............................................ 8
Initial Lighting............................................................... 31
Installation ................................................................... 12
Mandatory Requirements ............................................. 7
Sealed System Requirements...................................... 9
Servicing ...................................................................... 33
Short List of Parts ....................................................... 60
Terminal Guards ............................................................ 8
Thermostatic Radiator valves ...................................... 9
Unpacking .................................................................... 13
Water and Systems ...................................................... 8
Water Connections ...................................................... 6
Water Treatment ........................................................... 9
Wiring Diagrams.......................................................... 28
The CH flow temperature is controlled by an electronic thermostat.
In DHW mode the boiler modulates to sustain a nominal adjustable
water flow temperature of 60
The boiler casing is of white painted mild steel with a drop-down
controls access door.
The boiler temperature control is located behind the controls access
door.
The heat exchanger is made of copper and cast iron.
The system pipework must include drain cocks in appropriate
places. Pipework may be taken downwards or upwards behind
the boiler (using the stand-off channels).
o
C.
OPTIONAL EXTRA KITS
Programmer Kit - fits neatly within the casing. Separate fitting
instructions are included with the kit.
Note.
If using an alternative programmer read Frame 42 first.
Extension Ducts
Roof Flue kit
90o Elbow kit
45o Elbow kit
Powered Vertical Flue kit
Note.
When ordering Pack H or Pack K flue adaptor must
be used.
NOTE TO THE INSTALLER:
LEAVE THESE
INSTRUCTIONS ADJACENT TO THE GAS METER.
ALSO COMPLETE THE BENCHMARK LOG BOOK
AND GIVE THIS TO THE CUSTOMER.
4
Response 80 / 100 / 120
- Installation
GENERAL
OPERATION
With no call for CH the boiler fires only when DHW is drawn off.
When there is a call for CH, the heating system is supplied at the
selected temperature until DHW is drawn off. The full output of
the boiler is then directed by the automatic switching off of the
circulation pump to heat the inner coils and supply a maximum
1
BOILER W ATER CIRCUIT DIAGRAMS
draw-off of :
Response 80 9.6 l/min (2.1 gpm) at 35
Response 100 12.0 l/min (2.6 gpm) at 350 rise
Response 120 14.4 l/min (3.1 gpm) at 35
The nominal DHW temperature is 60 oC but water drawn off
when the boiler has been on for central heating may be hotter
than this, for a short period of time.
0
rise
0
rise.
Response 80 / 100 / 120
- Installation
5
GENERAL
2
BOILER DIMENSIONS, SERVICES & CLEARANCES
Boiler connections are made on the mounting frame. Refer to Frame
17.
The following minimum clearances must be
maintained for operation and servicing.
Additional space will be required for installation,
depending upon site conditions.
Side and Rear Flue
a. Provided that the flue hole is cut accurately,
e.g. with a core drill, the flue can be installed
from inside the building where wall
thicknesses do not exceed 600mm (24").
Where the space into which the boiler is
going to be installed is less than the length
of flue required the flue must be fitted from
the outside.
Installation from inside ONL Y
b. If a core boring tool is to be used inside the
building the space in which the boiler is to
be installed must be at least wide enough to
accommodate the tool.
all dimensions in mm (in.)
Front clearance
The minimum front clearance when built in to a
cupboard is 5mm (1/4") from the cupboard door
but 450mm (17 3/4") overall clearance is still
required, with the cupboard door open, to allow
for servicing. See Table 4.
CLEARANCES
Per side 5 mm
Top 160 mm (depth of elbow and lift
Front 450 mm clear of spigot space,
Bottom 150 mm internal wall ring plate)
* Bottom clearance
Bottom clearance after installation can be
reduced to 10mm in an adequately ventilated
enclosed cupboard. However, 150 mm must
be available for servicing.
6
Dimension y
Boiler only with stand-
off brackets
139mm 169mm
7/16") (6 5/8")
(5 (
Distance X is 20mm for DHW pipes and safety valve outlet.
Distance X is 23.5mm for CH pipes and gas inlet.
Response 80 / 100 / 120
- Installation
GENERAL
SAFETY
Current Gas Safety (Installation and Use) Regulations
or rules in force.
It is law that all gas appliances are installed and serviced by a
CORGI registered installer 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 the law is complied with.
The installation of the boiler MUST also be in accordance with
the latest I.E.E (BS.7671) Wiring Regulations, local building
regulations, bye-laws of the local water authority, the building
regulations and the Building Standards (Scotland) and any
relevant requirements of the local authority.
Detailed recommendations are contained in the following
British Standard Codes of Practice:
BS. 5440:1 Flues (for gas appliances of rated input not
exceeding 60 kW).
BS. 5440:2 Ventilation (for gas appliances of rated input not
exceeding 60 kW).
BS. 5449 Forced circulation hot water systems.
BS. 5546 Installation of gas hot water supplies for
domestic purposes (2nd Family Gases)
BS. 6700 Design, installation testing and maintenance of
services supplying hot water for domestic use.
BS. 6798 Installation of gas fired hot water boilers of rated
input not exceeding 60 kW.
BS. 6891 Low pressure installation pipes.
Health & Safety Document No. 635.
The Electricity at Work Regulations, 1989.
The manufacturer’s notes must NOT be taken, in any way, as
overriding statutory obligations.
IMPORTANT. These appliances are CE certificated for safety
and performance. It is, therefore, important that no external
control devices, e.g. flue dampers, economisers etc., are
directly connected to these appliances unless covered by
these Installation and Servicing Instructions or as otherwise
recommended by Caradon Plumbing Limited in writing. If in
doubt please enquire.
Timber Framed Buildings
If the boiler is to be fitted in a timber framed building it should be
fitted in accordance with the Institute of Gas Engineering
document IGE/UP/7:1998.
Bathroom Installations
This range of appliances is rated IP 1XB.
The boiler may be installed in any room or internal space,
although particular attention is drawn to the requirements of the
current I.E.E. (BS.7671) Wiring Regulations and, in Scotland, the
electrical provisions of the building regulations applicable in
Scotland with respect to the installation of the boiler in a room or
internal space containing a bath or shower.
If the appliance is to be installed in a room containing a bath or
shower then, providing water jets are not going to be used for
cleaning purposes (as in communal baths/showers), the
appliance can be installed in Zone 3, as detailed in BS.7671.
Where installation will be in an unusual location, special
procedures may be necessary and BS 6798 gives detailed
guidance on this aspect.
Compartment Installations
A compartment or cupboard, including airing cupboards, must
conform to the following:
! BS. 6798.
! For the minimum clearances required for safety and
subsequent service see the wall mounting template and
Frame 2. In addition, sufficient space will be required to allow
lifting access to the wall mounting plate.
! Ventilation of the compartment ,e.g. permanent high and low
level air vents, must be provided in accord with the current
issue of BS 5440, Part 2. See Table 4 and 'Air Supply' .
T able 4 - Minimum air vent free area for compartments /
cupboards (high and low levels)
Response Vent Air from room or Air direct from
Level internal space outside
80 High/Low 265 (41) 135 (21)
100 High/Low 317 (49) 158 (24)
120 High/Low 396 (62) 203 (32)
2
(in.2 ) - cm2 (in.2 )
- cm
Any direct connection of a control device not approved by
Caradon Plumbing Limited could invalidate the certification
and the normal appliance warranty. It could also infringe the
Gas Safety Regulations and the above regulations.
SAFE HANDLING OF SUBSTANCES
Care should be taken when handling the boiler insulation
panels, which can cause irritation to the skin. No asbestos,
mercury or CFCs are included in any part of the boiler.
LOCATION OF BOILER AND FLUE OUTLET
The boiler must be installed on a flat and vertical wall, capable
of adequately supporting the weight of the boiler and any
ancillary equipment.
The boiler may be fitted on a combustible wall and insulation
between the wall and the boiler is not necessary, unless
required by the local authority.
The boiler must not be fitted outside.
Response 80 / 100 / 120
- Installation
AIR SUPPLY
Detailed recommendations for air supply are given in
BS.5440:2. The following notes are for general guidance:
1. If the boiler is to be installed in a cupboard or compartment,
permanent air vents are required (for cooling purposes) in
the cupboard/compartment at both high and low levels. The
air vents must either communicate with room/internal space
or be direct to outside air. The minimum effective areas of the
permanent air vents required in the cupboard/compartment
are specified in Table 4 and are related to maximum rated
heat input.
2. Both air vents MUST communicate with the same room or
internal space or MUST be on the same wall to outside air.
3. In siting the air vents, care must be taken to avoid the freezing
of pipework.
4. If the boiler is NOT installed in a cupboard or compartment no
air vent is necessary.
7
GENERAL
GAS SUPPLY
The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an adequate
supply of gas. An existing service pipe must NOT be used without
prior consultation with the local gas supplier.
A gas meter can only be connected by the local gas supplier or
by a registered CORGI installer.
Check that the appliance is suitable for the proposed gas supply.
A working gas pressure of 20 mbar MUST be available at the
boiler inlet.
IMPORT ANT.
Installation pipes MUST be fitted in accordance with BS. 6891.
Pipework from the meter to Response boilers MUST be of an
adequate size, i.e. not less than 22mm O.D. copper or
3/4" BSP iron.
The complete installation MUST be tested for gas soundness
and purged as described in the above code.
Table 5 - Gas Supply
Total length of supply pipe (metres)
9 121520253540 4550
Gas
Discharge
Note.
160 140 120 100 89 74.2 67.1 63.6 60 22
ft3 / h
330 280 250 210 180 151.9137.7 130.7 123.6 28
Each fitting used in the gas line from the meter is equivalent
to a length of straight pipe which must be added to the straight
pipe length to give the total length. i.e.: bend = 0.5 metres, Tee =
0.5 metres, 90o elbow = 0.3 metres.
Pipe size
(mm Dia.)
FLUE INSTALLATION
The flue must be installed in accordance with the
recommendations of BS. 5440: Part 1.
The following notes are intended for general guidance:
1. The boiler MUST be installed so that the terminal is
exposed to external air.
2. It is important that the position of the terminal allows the
free passage of air across it at all times.
3. Minimum acceptable spacing from the terminal to
obstructions and ventilation openings are specified in
Table 6.
4. Where the lowest part of the terminal is fitted less than 2m
(6'6") above a balcony, above ground or above a flat roof to
which people have access then the terminal MUST be
protected by a purpose designed guard. The minimum
spacing in Table 6, Nos. 2, 3, 4, 5 and 6 would be 75mm, in
order to allow a terminal guard to be fitted.
Terminals guards are available from boiler suppliers - ask
for TFC Guard, Model K1. In case of difficulty contact:
Grasslin (UK) Ltd., Tower House, Vale Rise, Tonbridge,
Kent TN9 1TB. Tel: 01732 359888. Fax: 01732 354445.
www.ffc.ukco.com
Ensure that the guard is fitted centrally.
5. The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of any building.
6. The air inlet/products outlet duct and the terminal of the
boiler MUST NOT be closer than 25mm (1") to combustible
material. Detailed recommendations on the protection of
combustible material are given in BS. 5440: 1990.
Table 6 - Balanced flue terminal position
Approved Manufacturer's Clearance
These clearances are for horizontal flue only. For vertical
N.B.
clearances see the publication for Pack K/Pack H.
Note (Positions 2-6)
: Due to the terminal design, installation
is possible with clearances less than those specified in BS
5440, Part 1.
Terminal Position
1. Directly below or alongside an
opening window, air vent or other
ventilation opening 300 mm (12")
2. Below guttering, drain pipes or soil
pipes 25 mm ( 1")
3. Below eaves 25 mm ( 1")
4. Below balconies or a car port roof 25 mm ( 1")
5. From vertical drain pipes or soil pipes 25 mm ( 1")
6. From internal or external corners 25 mm ( 1")
7. Above adjacent ground, roof or
balcony level 300 mm (12")
8. From a surface facing the terminal 600 mm (24")
9. From a terminal facing a terminal 1200 mm (48")
10. From an opening in a car port
(e.g. door or window) into dwelling 1200 mm (48")
11. Vertically from a terminal on the
same wall 1500 mm (60")
12. Horizontally from a terminal on the wall 300 mm (12")
Minimum Spacing
7. Where it is essential that the terminal wall plate
wall thicknesses over 610mm (24") or with an inaccurately
cut hole, the minimum spacing in Table 6, Nos. 2, 3, 4, 5
and 6 would be 60mm (2.4") in order to allow the terminal
wall plate to be fitted.
IMPORTANT. It is the responsibility of the installer to ensure, in
practice, that products of combustion discharging from the
terminal cannot re-enter the building or any other adjacent
building through ventilators, windows, doors, other sources of
natural air infiltration, or forced ventilation / air conditioning.
If this should occur the appliance MUST be turned OFF,
labelled as 'unsafe' until corrective action can be taken.
is fitted, i.e.
FLUE LENGTHS
The flue assembly can be adapted to accommodate flue
lengths up to 3 metres for the 80 and up to 4m for the 100 and
120. Refer to Frame 10.
WATER CIRCULATION SYSTEM
The boilers are designed for connection to pressurised, fully
pumped, sealed water central heating systems ONLY. The
domestic hot water (DHW) calorifier is incorporated within the
heat exchanger and only requires connection to the mains
water supply.
IMPORT ANT.
Copper tubing to BS2871:1 MUST be used throughout the
heating and domestic hot water systems.
8
Response 80 / 100 / 120
- Installation
GENERAL
Ensure that the mains water supply pressure is adequate to
provide the required DHW flow rate.
Refer to Table 1 on page 3.
The central heating system should be installed and
commissioned in accordance with BS. 6798 and, in addition,
for smallbore and microbore systems BS. 5449.
The domestic hot water system should be in accordance with
BS. 5546 and BS. 6700.
Any soldered joints on potable water pipework MUST NOT be
made with solder containing lead.
Ancillary pipework not forming part of the useful heating
surface should be lagged to prevent heat loss and any
possible freezing - particularly where pipes run through roof
spaces or ventilated underfloor spaces.
Draining taps should be at least
in accordance with BS 2879.
Maximum recommended system hydraulic losses are given in
the Table within Frame 5.
1/2" BSP nominal size and be
WA TER TREA TMENT
Antifreeze fluid, corrosion and scale inhibitor fluids suitable for
use with boilers having copper heat exchangers may be used
in the central heating system.
For further information contact either:
Fernox Manuf. Co. Ltd or G E Betz Ltd.,
Tandem House Widnes
Marlowe Way Cheshire
Croydon, Surry CRO 4XS
Tel. 0870 601 5000 Tel: 0151 424 5351
THERMOSTATIC RADIATOR VALVES (TRV)
Caradon Plumbing Limited recommend that heating systems
utilising full thermostatic radiator valve control of temperature
in individual rooms should also be fitted with a room
thermostat controlling the temperature in a space served by
radiators not fitted with such a valve as stated in BS. 5449.
When thermostatic radiator valves are used, the space
heating temperature control over a living area having a heating
requirement of at least 10% of the boiler heat output should be
achieved using a room thermostat whilst other rooms are
individually controlled by thermostatic radiator valves.
For further information refer to the 'Good Practice Guide 143', a
publication of the Energy Efficiency Office, available from the
Building Research Establishment, Garston, Watford WD2
7JR. Tel: 01923 664258.
ELECTRICAL SUPPLY
WARNING.
Wiring external to the appliance MUST be in accordance with
the current I.E.E. (BS.7671) Wiring Regulations and any local
regulations which apply.
The point of connection to the mains should be readily
accessible and adjacent to the boiler, except for bathroom
installations where the point of connection to the mains MUST
be situated outside of the bathroom.
Note.
containing a bath or shower then the appliance and any
electrical switch or appliance control utilising mains electricity
should be so situated that it cannot be touched by a person
using the bath or shower.
This appliance must be efficiently earthed.
Where a room sealed appliance is installed in a room
3
SEALED SYSTEM REQUIREMENTS - Central Heating
Note.
Response combination boilers are suitable for
3. Flow Temperature
fully pumped pressurised sealed systems only.
REQUIREMENTS
1. General
Any method of filling, refilling, topping up or flushing
sealed primary hot water circuits from the mains via a
temporary hose connection is only allowed if it complies
with Water Bye-law 14, which states:
" (1) No closed circuit shall be connected to a supply pipe.
(2) Paragraph (1) shall not apply to a temporary connection
provided that:
a. The connection is made through a double check valve
assembly or some other no less effective device which
is permanently connected to that circuit;
and
b. The temporary connection is removed after use. "
The method described in this instruction complies with
that Bye-law.
2. BS. Requirements
The installation must comply with the requirements of
BS. 6891:1988 and BS. 5449.
4. Working Pressure
The installation should be designed to work with flow
temperatures of up to 90° C.
All components of the system must be suitable for a
working pressure of 3 bar (45 lb/in2 ) and temperature of
110°C. Extra care should be taken in making all
connections so that the risk of leakage is minimised.
The following components are incorporated within the
appliance:
a. Circulating pump.
b. Safety valve; with a non-adjustable pre-set lift
pressure of 3 bar (45lb/in
c. Pressure gauge; covering a range of 0-6 bar.
d. 8-litre expansion vessel; with an initial charge
pressure of 1 bar (15 lb/in2).
e. Domestic hot water (DHW) mini expansion vessel.
For further details refer to BS.5449:1 and the British Gas
Corporation publication 'Specifications for Domestic
Central Heating and Hot Water'.
2
).
Response 80 / 100 / 120
- Installation
9
GENERAL
4
SEALED SYSTEM REQUIREMENTS - Central Heating - continued
5. Filling the system
Fill the system through a temporary hose connection
from a draw-off tap supplied from a service pipe under
mains pressure. Where the mains pressure is excessive
a pressure reducing valve shall be used to facilitate filling.
The following fittings shall form a permanent part of the
filling system:
A double non-return valve with at least 1 isolation valve,
which is used as a temporary connection to fill the system
from the mains, after which it should be disconnected
and left with the installation.
Proceed with the following:
• Thoroughly flush out the whole of the system with
cold water before fitting the boiler.
• Fill and vent the system until the pressure gauge
registers 1.5 bar (22 lb/in
• Release water from the system until a pressure of
1 bar (15 lb/in
2
) is reached. To avoid getting debris
2
). Examine for leaks.
on the valve seat, do not use the safety valve to do
this.
• Light the boiler and heat the system to the
maximum working temperature. Examine for
leaks.
• Turn off the boiler and drain the system while still
hot.
• Refill and vent the system.
CH Return
(disconnect after filling)
Ecl 6053
6. Size of expansion vessel
For the system water expansion to be contained by the
8-litre expansion vessel fitted to the boiler the cold
system volume must not exceed:
119 litres when pressurised to 0.5 bar (cold)
107 litres when pressurised to 0.7 bar (cold)
91 litres when pressurised to 1.0 bar (cold)
If the pressure exceeds 2.65 bar when the boiler is up
to temperature with all radiators in use then an
additional expansion vessel MUST be installed on the
return pipework.
For expansion volumes see table below.
Hose unions
Temporary hose
Mains
water supply
Additional
stop valve
Double check valve
assembly
(
note direction of flow)
• Re-pressurise the system to the desired charge
pressure (see table below ).
Vessel sizing / Expansion volumes
System charge pressure (bar) 0.5 0.7 1.0
Safety valve setting (bar) 3.0
Vessel pre-charge pressure (bar) 0.5 0.7 1.0
System volume litres V olume of expansion vessel in
75 None None None
100 None None 0.8
125 0.4 1.3 3.0
150 2.1 3.1 5.1
175 3.8 4.1 7.3
200 5.4 6.8 9.5
225 7.1 8.7 11.7
250 8.8 10.5 13.9
275 10.6 12.4 16.1
300 12.2 14.2 18.4
Multiply this factor by system volume and
deduct 8 litres to obtain size of additional 0.067 0.074 0.088
vessel for other system volumes.
Guidance on vessel sizing is given below and also in
BS 7074:1 and BS 5449.
addition to 8-litre unit fitted to boiler
10
Response 80 / 100 / 120
- Installation
GENERAL
5
SEALED SYSTEM REQUIREMENTS - Central Heating - continued
7. Thermostatic radiator valves.
Caradon Plumbing Limited support the
recommendations made by leading manufacturers of
domestic heating controls that heating systems utilising
full thermostatic radiator valve control of temperature in
individual rooms should also be fitted with a room
thermostat controlling the temperature in a space served
by radiators not fitted with such a valve. Such an
arrangement will provide for a more efficient control of the
environment and will also avoid the continuous running
of the circulation pump during programmed heating ON
periods, saving electrical energy.
IMPORT ANT.
It is therefore strongly recommended that, when
thermostatic radiator valves are used, the space heating
temperature control over a living/dining area or a hallway,
having a heat requirement of at least 10% of the boiler
output, is achieved using a room thermostat whilst other
rooms are individually controlled by thermostatic radiator
valves.
However, if thermostatic radiator valves are fitted to all
radiators then a bypass MUST be fitted. This should
consist of 22mm (
boiler as possible and incorporating a balancing valve
3/4") pipe positioned as far from the
which cannot be adjusted by the householder.
For adjustment refer to Frame 45.
a. The total length of pipework A, B, C & D
be less than 3m (10') and must not include any other
valves.
b. The balancing valve MUST be at least one turn open.
8. Hydraulic resistance
Having subtracted the hydraulic resistance of the boiler
the head available to overcome system resistance at
MAXIMUM CENTRAL HEATING OUTPUT, with an 11
(20oF) temperature differential, is shown in the table.
MUST NOT
Water Flow Rate and Pressure Loss
Response Response
80 100/120
Max CH Output kW 17.6 23.4
(Btu/h) (60 000) (80 000)
Water flow rate l/sec 0.382 0.508
(gal/min) (5.04) (6.7)
o
Temperature
differential (oF) (20) (20)
Head available for m.w.g. 2.75 2.5
system pump, pos.3 (ft.w.g.) (9.0) (8.0)
9. Draining the system
Draining taps MUST be located in accessible positions
to permit the draining of the whole central heating
system, including the central heating side of the boiler.
The taps should be at least 1/2" BSP nominal size and
be in accordance with BS 2879. The boiler flow and
o
C
return service valves (fitted to the piping frame) have
drain plugs to drain the BOILER ONLY, in the event of
the system drain tap being unable to do so.
C11 11
6
DOMESTIC HOT WATER REQUIREMENTS
1. The domestic hot water service must be in accordance
with BS 5546 and BS 6700.
2. For the minimum and maximum working pressures of
the Response domestic hot water circuit refer to Table
1, page 3.
However in areas where DHW inlet pressures are
greater than 2 bar a water pressure governor should
be fitted to ease commissioning
3. The cold water supply pipe should be flushed before
fitting the boiler.
It is the responsibility of the installer to ensure that the
DHW inlet is free from debris.
4. The boilers are suitable for connection to most types of
washing machine and dishwashing appliances.
5. When connecting to suitable showers, i.e. those
designed for modulating domestic hot water, ensure that:
a. The cold inlet to the boiler is fitted with an approved
anti-vacuum or syphon non-return valve.
b. Hot and cold supplies are of equal pressure.
Response 80 / 100 / 120
- Installation
6. Hard water areas
In areas where the water is 'hard' it is recommended that a
proprietary scale-reducing device is fitted into the boiler
cold supply, within the requirements of the local water
company.
7. DHW Filter
A filter is provided for fitting to the DHW inlet connection.
This filter MUST be fitted in ALL installations.
Refer to the adjoining table for the minimum DYNAMIC inlet
water pressure required to achieve maximum boiler output.
Boiler Water Pressure
Response 80 1.0 bar
Response 100 1.2 bar
Response 120 1.2 bar
11
7
INSTALLATION
INST ALLATION
BOILER ASSEMBLY - Exploded View
LEGEND
A. Gas injection pipe.
B. Pressure gauge sub assy.
C. Flue outlet elbow
D. Wall mounting plate
1. Main burner
2. Main burner injector
3. Gas valve
4. Flame sensing electrode
5. Ignition electrode
7. PCB 41
8. PCB 40
9. PCB 8: Fan speed
controller.
12
11. Boiler overheat t'stat.
12. Water pressure switch.
13. DHW O/heat t'stat.
14. DHW sensor.
15. Potentiometer harness.
16. Potentiometer knob
17. Pressure gauge.
19. Fan assembly.
21. Pressure relief valve.
22. DHW expansion vessel
23. CH expansion vessel
24. Pump.
25. DHW Flow switch.
26. Automatic air vent.
27. Heat exchanger.
28. Pressure sensing pip
30. EMC filter.
32. CH Return pipe assy.
33. Pump pipe assy.
34. CH Lower flow pipe assy.
35. CH Upper flow pipe assy.
36. DHW Upper cold pipe assy.
37. DHW Upper hot pipe assy.
38. DHW Lower cold pipe assy.
Response 80 / 100 / 120
39. DHW Lower hot pipe
assy.
40. Boiler front panel.
41. Sealing panel
44. Tank cover assy
45. Controls door assy.
59. Turret clamp.
67. Transformer.
- Installation
INST ALLATION
8
UNPACKING
The boiler is supplied fully assembled in one Pack A, together with a standard
flue assembly for lengths up to 600mm, rear or side flue outlet, in Pack B.
Unpack and check the contents.
Pack A Contents
! The boiler.
! These Installation & Servicing Instructions.
! The User's Instructions.
! Wall mounting template.
! Wall mounting frame.
! 1 pair stand-off channels (optional use).
! Flue turret.
! Clamping and sealing ring.
! Mains connector assy.
! Hardware Pack.
! Coupling Hardware Pack.
Hardware Pack
! M6 x 16 Pp. Hd. screw - 4 off.
! 1/2" x 15mm copper connector - 1 off.
! No.14 x 2" slotted Rd. Hd. screw - 6 off.
! Wall plug (brown) - 6 off.
! 1/2" Nut - 2 off.
! M28 Nut - 2 off.
! 22mm pipe connector - 2 off.
! 15mm pipe connector - 2 off.
! 22mm x 15mm reducing coupling - 1 off.
! Pressure relief valve drain pipe - 1 off.
! Pressure relief valve nut - 1off.
! Gas pipe assy. - 1 off.
! 22mm olive - 2 off.
! 15mm olive - 3 off.
! 26mm Sealing washer - 3 off.
! 12mm Sealing washer - 3 off.
INSTALLATION
Pack B Contents
! Terminal grille assembly
! No.8 x 8mm self tapping screw - 3 off
! No.10 x 2" slotted Rd. Hd. screw - 4 off
! Flue support cutting aid - 1 off
! Wall plugs - 4 off
! Terminal wall plate - 1 off
9
PACKAGING AND FRONT PANEL REMOVAL
1. Remove the lid.
2. The top tray contains:
! Flue turret
!"Mounting frame
!" Hardware pack
!" Stand-off channels
!" Wall mounting template
!" Installation instructions
Coupling Hardware Pack.
! 28 x 22 mm straight coupling.
Filter Hardware Pack.
! DHW inlet filter
These contents can be removed, leaving the boiler in its protective package.
Response 80 / 100 / 120
- Installation
13
INST ALLATION
10
DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED
USE A MAXIMUM OF 3 EXTENSION DUCTS
ONL Y FOR THE 80 AND A MAXIMUM OF 4
EXTENSION DUCTS FOR THE 100 AND 120.
When using 90o elbow kits, each elbow is
equivalent to 1 metre flue length.
INSTALLATION
Calculate the total length of flue by the following:
Rear flue length = Dim. W + 79mm (3
Rear flue length with stand-off channels = Dim. W + 109mm (4 3/8")
RHS flue length = Dim. R + 220mm (8
LHS flue length = Dim. L + 96mm (3
Note.
These figures include the length of flue entering the flue turret
socket.
1/8")
5/8")
3/4
")
Flue Kit Requirements
T otal Length of Flue Extra Packs Required
* 600mm (23 5/8") None
*1600mm (63") One Pack D
2600mm (102 3/8") Two Pack D
3000mm (118
4000mm (157
Pack B - supplied as standard.
Pack D - optional extra kit, to extend the flue.
1/8") Three Pack D
1/2") Four Pack D**
14
* N.B.
If the measured flue length is only just above these sizes, it
may be necessary to shorten the standard flue before adding
extension duct(s), in order to prevent interference between
flue duct connections and the boiler flue elbow.
**
4000mm maximum for the 100 and 120 only.
For side flue option
PROCEED TO FRAME 20
Response 80 / 100 / 120
.
- Installation
11
REAR FLUE ASSEMBLY - Exploded View
LEGEND
1. Terminal.
2. Weather seal.
3. Duct assembly.
4. Sealing ring.
5. Clamping ring.
6. No.8 x 8 self tapping screw.
7. Flue turret.
8. M5 x 10 pozi Hex screw.
9. Turret clamp.
12
WALL MOUNTING TEMPLATE (Rear Flue)
IMPORTANT.
For direct mounting (wall mounting frame on wall)
choose one black dot in each group.
INST ALLATION
If using the stand-off channels choose one dotted circle
in each group. Care MUST be taken to ensure the
correct holes are drilled.
1. Tape the template into the selected position.
2. Ensure squareness by hanging a plumbline as
shown.
3. Mark onto the wall the following:
a. The 6 wall mounting plate screw positions.
b. The position of the flue duct.
Mark the centre of the hole as well as the circumference.
4. Remove the template from the wall.
13
DRILLING THE W ALL (Rear Flue)
IMPORTANT. Ensure that, during the cutting operation,
masonry falling outside the building does not cause damage
or personal injury.
1. Cut the flue hole (preferably with a 5" core boring tool),
ensuring that the hole is square to the wall.
2. Measure and note the wall thickness 'W'.
3. Drill the 6 fixing holes with an 8mm (
Note.
If the terminal is to be sited within 25-40mm of a
corner or vertical pipe (refer to Table 5) then the hole MUST
be accurately cut and the rubber weather seal trimmed
around the groove provided.
(The terminal wall plate cannot be fitted close to a corner).
Response 80 / 100 / 120
- Installation
5/16") masonry drill.
REAR FLUE OUTLET
15
INST ALLATION
14
FITTING THE W ALL MOUNTING FRAME
Fit the wall mounting frame either:
a. Directly to the wall
!!
! Insert wall plugs.
!!
!!
! Put the screws into the wall plugs and leave 10mm proud
!!
!!
! Hang the frame onto the screws and tighten up.
!!
or
b. Use stand-off channels
(To allow pipework to be taken upwards).
!!
! Insert wall plugs.
!!
!!
! Put the screws into the wall plugs and leave 10mm proud.
!!
!!
! Fasten each channel to the frame with the 6mm screws
!!
provided.
!!
! Hang the channels and frame onto the screws and tighten
!!
up.
If the clearances above and below the boiler are less
Note.
than the length of the pipes it will be necessary to position the
pipes behind the wall mounting plate BEFORE the plate is
screwed to the wall.
Showing the use of 'stand-off' channels,
to enable upward pipework.
Make service water, gas & electrical connections. Go to Frames 35, 36 & 39 then return to Frame
REAR FLUE OUTLET
15.
16
Response 80 / 100 / 120
- Installation
INST ALLATION
15
CUTTING THE FLUE - Wall thicknesses up to 600mm (23 5/8")
1. The flue cut length is
calculated as detailed in
Frame 10.
2. Measure from the groove and
mark the tube.
3. To ensure the tube is cut
square, mark the flue all the
way round using (e.g). a long
straight strip of paper with its
ends overlapped.
4. Cut to length, using the
cardboard support aid.
5. Remove the cardboard
support and any burrs.
For flue lengths greater than 600mm (23 5/8") refer to Frames 30 to 32 Flue Extension Ducts
16
FITTING THE FLUE
IMPORTANT
To facilitate turret fixing or removal do NOT make good the wall.
1. Attach the clamping/sealing rings to the flue (this prevents the
assembly being pushed right through the hole and causing an
accident).
2. Pass the cut flue through the prepared hole, ensuring that the
groove is uppermost.
3. Pull the flue back to compress the rubber seal and fix in place
with the clamping/sealing rings.
Response 80 / 100 / 120
- Installation
REAR FLUE OUTLET
17
INST ALLATION
17
MOUNTING THE BOILER
1. The boiler may be prewired to the loose electrical
connector and secured with the cable clamps. Refer
to Frame 39.
WARNING. ENSURE
2.
removed from both the DHW and CH pipes before
mounting.
N.B. Some spillage of water may occur from the
pipework when mounting the boiler to the frame.
3. Lift the boiler onto the wall mounting frame, locating it
over the tabs at the top of the frame.
4. Lower the boiler into position.
5. Remove the bottom panel to access service
connections.
6. Fit the filter to the DHW inlet valve,
as shown.
7. Using the correctly sized fibre
washers supplied in the hardware
pack, engage and then tighten the
4 water unions.
8. Engage and tighten the gas union.
9. Fix the pipe and fibre washer to the
safety drain outlet which is supplied
in the boiler hardware pack.
that the plastic plugs are
18
CONNECTING THE TURRET TO THE BOILER
1. Mate the turret to the flue.
2. Secure the flue turret on top of the
boiler by inserting the open ends of
the turret clamp under the 2 studs
and fixing it in the middle with the
single M5 x 10mm pozi-hex screw
provided.
3. Drill a 3.2mm hole through the flue
via the hole already present in the
turret. Secure the turret to the flue,
using the self-tapping screw
provided.
REAR FLUE OUTLET
18
Response 80 / 100 / 120
- Installation
INST ALLATION
19
TERMINAL WALL PLATE
This plate allows neat concealment and full
compression of the rubber seal. It should be used,
where practicable::
a. When the wall is more than 24" thick (to support the
flue weight and prevent movement).
or
b. When the hole has not broken through neatly.
or
c. When the wall face is rough and the rubber seal on
its own would be ineffective.
1. Position the terminal wall plate over the terminal.
2. Drill 4 fixing holes with a 7mm (
3. Insert the 4 plastic plugs provided in flue pack B.
4. Secure the plate with 4 of the No.10 x 2" screws provided
in flue pack B.
Note.
If the terminal is less than 2m (6' 6") above ground
level, an approved terminal guard should be fitted.
Refer to 'Flue Installation', Page 7.
1/4") masonry drill.
Response 80 / 100 / 120
- Installation
REAR FLUE OUTLET
19
20
SIDE FLUE ASSEMBLY - Exploded View
1. An optional flue duct extension kit is
required for wall thicknesses greater
than:
INST ALLATION
504mm (19
380mm (15") - RHS flue
Refer to Frame 10.
2. When cutting the ducts
always use the cardboard
support cutting aid
provided.
21
WALL MOUNTING TEMPLATE (Side Flue)
IMPORTANT.
For direct mounting (frame on wall) choose one black dot in each group.
If using the stand-off channels choose one circle in each group.
Care MUST be taken to ensure the correct holes are drilled.
7/8") - LHS flue
LEGEND
1. Terminal
2. Weather seal
3. Sealing ring
4. Clamping ring
5. Duct assembly
6. Flue turret
7. Turret clamp
8. M5 x 10 pozi-hex screw
9. No. 8 x 8 fixing screw
Note.
When marking off the flue allow for the
stand-off channels if using them. Read
SIDE FLUE OUTLET
the notes on the template.
1. Tape template into the selected
position.
2. Ensure squareness by hanging
a plumbline, as shown.
3. Mark onto the wall the following:
a. The 6 wall mounting plate
screw positions (choose
one from each group).
b. Extended the centre line as
shown. Mark the flue duct
centre from the corner (see
diagram and template).
Mark the centre of the hole
Note.
as well as the circumference.
4. Remove template from the wall.
20
Response 80 / 100 / 120
- Installation
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