Navien NCM-1130HH Installation Instructions Manual
Country of destination : GB
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Safety Definitions
All safety messages will refer to potential hazards. Precisely
follow the Instructions to avoid the risk of injury.
List of safety symbols in the instructions
This is the safety alert symbol. It is used to alert you of potential
personal injury
hazards.
Adhere to all safety messages that follow this symbol to avoid possible injury or
death.
Indicates an imminently hazardous situation which, if not avoided, could result in minor or
moderate injury.
CAUTION
Used without the safety alert symbol indicates a potential hazardous situation which, if not
avoided, could result in property damage.
Indicates an imminently hazardous situation which, if not avoided, could result in severe
injury or death.
Indicates an imminently hazardous situation which, if not avoided, could result in severe
injury or death.
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Sysmbols Used in the Instructions
The following symbols are used throughout the instructions to bring attention to the important
information concerning the appliance.
Important Safety Precautions
If you can smell gas
Gas Leaks can cause explosions, which
may lead to serious injury.
Do not smoke. Prevent open flames and
sparks.
Do not operate light switches or electrical
equipment switches.
Open the windows and doors.
Close the gas shutoff valve.
Shut down the heating system.
Keep people away from the danger zone.
Observe the safety regulations of your
local gas supplier, found on the gas meter.
Notify your heating contractor from the
outside of the building.
Flue gas may lead to life-threatening
poisoning.
Shut down the heating system.
Ventilate the location.
Close all doors leading to lining spaces.
Do not operate electrical switches.
Working on the heating system
Isolate the system from the main
electrical power supply, e.g.by removing a
separate fuse or by means of a main
electrical isolator, and check that it is no
longer “live”.
Isolate the gas supply and safeguard it
from unauthorized reopening.
For propane appliances
Purging the liquid gas tank when
installing the system:
Before installing the appliance make sure
that the gas tank has been purged. The
liquid gas supplier is responsible for
properly purging the tank. Ignition
problems may occur if the tank is not bled
properly. In such cases, first contact the
person in charge of filling the tank.
Indicates additional information that is important but not related to personal injury or
property damage
Warns of a risk of material loss and environmental pollution.
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Contents
1.0 GENERAL INFORMATION .......................................................................................... 6
1.1 P
RODUCT DESCRIPTION
.................................................................................................. 6
1.2 C
ERTIFICATION DETAILS
................................................................................................. 7
1.2.1 Scope of certification .......................................................................................... 7
1.3 H
AZARD
.................................................................................................................... 7
1.4 C
ONTROL OF SUBSTANCES HAZARDOUS TO HEALTH
................................................................. 8
1.5 M
AINTENANCE AND SERVICING
......................................................................................... 8
2.0 TECHNICAL SPECIFICATIONS ................................................................................... 9
2.1 P
ERFORMANCE DATA AND GENERAL SPECIFICATIONS
................................................................. 9
2.2 M
INIMUM INSTALLATION AND SERVICE CLEARANCES
............................................................... 10
2.3 F
LUE SYSTEM SPECIFICATIONS
........................................................................................ 11
2.3.1 Horizontal flue systems. .................................................................................... 11
2.3.2 Vertical flue systems ......................................................................................... 12
2.3 KD NAVIEN
APPLIANCE INTERNALS
................................................................................. 14
3.0 INSTALLATION REQUIREMENTS ............................................................................. 15
3.1 S
TATUTORY REQUIREMENTS
........................................................................................... 15
3.2 P
RODUCT POSITION
..................................................................................................... 16
3.3 F
LUE TERMINAL LOCATION
............................................................................................. 16
3.4 C
ENTRAL HEATING SYSTEM
............................................................................................. 18
3.4.1 Hydraulic resistance .......................................................................................... 20
3.4.2 Water treatment ............................................................................................... 20
3.5 G
AS SUPPLY
.............................................................................................................. 20
3.6 Electricity supply ................................................................................................. 21
3.7 C
ONDENSATE DRAIN
.................................................................................................... 21
4.0 INSTALLATION PROCEDURE ................................................................................... 22
4.1 U
NPACKING
.............................................................................................................. 22
4.2 P
REPARING THE WALL FOR INSTALLATION
............................................................................ 23
4.2.1 Fitting the wall mounting template...................................................................... 23
4.3 M
OUNTING THE APPLIANCE
............................................................................................. 25
4.3.1 Lifting Equipment ............................................................................................. 25
4.3.1.1 Use of Lifting Gear .................................................................................................... 25
4.4 C
ONDENSATE DRAIN
.................................................................................................... 26
4.5 G
AS CONNECTION
...................................................................................................... 29
4.6 H
EATING SYSTEM CONNECTION
........................................................................................ 30
4.7 P
RESSURE REILEF VALVE
............................................................................................... 31
4.8 F
LUE SYSTEM PREPARATION
............................................................................................ 31
4.8.1 For a concentric flue system .............................................................................. 31
4.8.2 For a separate flue system................................................................................. 31
4.9 E
LECTRICAL CONNECTION
.............................................................................................. 33
4.9.1 General ........................................................................................................... 33
4.9.2 Appliance Loom Schematic Diagram .................................................................... 35
4.9.3 Accessing the Controller Assembly ...................................................................... 42
4.9.4 Accessing All the Electricity Connections .............................................................. 43
4.9.5 KD NAVIEN external control options .................................................................... 45
4.9.6 Connecting external valve and sensors ................................................................ 47
5.0 COMMISSIONING AND TESTING ............................................................................. 49
5.1 E
NGINE TRANSIT BRACKETS
........................................................................................... 49
5.2 E
LECTRICAL INSTALLATION
............................................................................................ 50
5.3
GAS INSTALLATION
..................................................................................................... 52
5.4 F
ILLING THE CENTRAL HEATING CIRCUIT
. ............................................................................ 52
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5.5 C
OMMISSIONING THE APPLIANCE
...................................................................................... 53
5.5.1 Starting the appliance ....................................................................................... 54
5.5.2 Commissioning the burners ............................................................................... 55
5.5.3 Adjusting gas valve for combustion specification .................................................. 56
5.6 F
INAL CHECKS
........................................................................................................... 58
5.6.1 Fitting the product casing .................................................................................. 58
5.6.2 General Checks ................................................................................................ 58
5.6.3 Product programmer unit operation .................................................................... 59
5.6.3.1 General description ................................................................................................... 59
5.6.3.2 Setting time and day................................................................................................. 61
5.6.3.2 User Levels .............................................................................................................. 63
5.6.3.3 Programming the appliance ....................................................................................... 65
5.6.3.4 Selecting heating mode ............................................................................................. 66
5.6.3.5 Adjusting the room temperature set point ................................................................... 67
5.6.3.6 Occupancy Button .................................................................................................... 67
5.6.3.7 Displaying information .............................................................................................. 67
5.7 H
ANDING OVER
......................................................................................................... 69
6.0 FAULT FINDING ...................................................................................................... 70
6.1 G
ENERAL
................................................................................................................. 70
6.2 E
RROR DISPLAY
......................................................................................................... 70
6.2.1 Error Code Subsystem ...................................................................................... 70
6.4 E
RROR CODES
........................................................................................................... 74
7.0 ROUTINE SERVICING .............................................................................................. 80
7.1 G
AS EMISSIONS
......................................................................................................... 80
7.2 C
HIMNEY SWEEP FUNCTION
........................................................................................... 80
7.3 G
ENERAL INSPECTIONS
................................................................................................. 81
7.4 S
ERVICING SUPPLEMENTARY BURNER
................................................................................ 81
7.6 C
HECKING & ADJUSTING THE IGNITION AND IONIZATION ELECTRODE
........................................... 83
7.7 C
LEANING HEAT EXCHANGER SURFACES
.............................................................................. 83
7.8 C
ONDENSATE TRAP
..................................................................................................... 83
7.9 E
NGINE BURNER
......................................................................................................... 84
7.10 RE-
ASSEMBLY
.......................................................................................................... 84
7.11 RE-
COMMISSIONING
.................................................................................................. 84
7.12 F
INAL CHECKS
......................................................................................................... 84
8.0 SHORT SPARE PARTS .............................................................................................. 85
8.1 G
ENERAL
................................................................................................................. 85
8.2 S
HORT SPARE PARTS LIST
............................................................................................. 86
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1.0 General Information
1.1 Product description
The KD NAVIEN product is a fully automatic, wall mounted, pre-mix room sealed fan powered,
balanced flue gas domestic combined heat and power unit for use with G25/G20 natural gas only.
The product incorporates a Stirling engine delivering up to 1.1 kW of electrical power and a fully
modulating gas control system with direct burner ignition.
The KD NAVIEN NCM-1130HH product has a 30kW heat output.
The product incorporates a stainless steel heat exchanger.
The product is designed for use with open vented primary fully pumped water systems and also
sealed systems up to 3 bar, with an indirect hot water cylinder.
Note that if thermostatic radiator valves are installed, the thermostat must be in the same room
as a lock shield radiator.
The product incorporates an electronic fault diagnosis system and display to facilitate rapid
identification of any fault conditions. Incorrect use of this product constitutes a safety hazard.
The product must at all times be operated in accordance with these and the KD NAVIEN NCM1130HH User Instructions as well as any subsequent instructions issued by KD NAVIEN.
This product shall be installed by appropriately trained KD NAVIEN engineers and in accordance
with the current Gas Safety (Installation and Use) Regulations (GSIUR) and also relevant Building
Regulations (particularly Part P)
All installation electrical work must be carried out ONLY by a trained electrician to the
requirements of the current edition IEE Requirements for Electrical Installation (BS 7671) and
Engineering recommendation G83 /1 – for the connection of small-scale embedded generators
(SSEG)(up to 16A per phase) in parallel with public low-voltage distribution networks.
In addition, all proposed work on the domestic mains electricity circuits in the users premises
must be notified to KD NAVIEN before work commences for the entire period of the trial.
Before commencing any electrical work in the property the product must be isolated at the
securable isolator and the gas cock turned off
.
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1.2 Certification Details
This product is CE marked under the following regulations.
The product is certified to comply with the following requirements:
Directives
Directive 2009/142/EC The Gas Appliance Directive
Directive 2006/95/EC The Low Voltage Directive
Directive 2004/108/EC The Electromagnetic Compatibility Directive
The following main standards are applied to achieve the directives
EN 483: 1999 Room sealed boilers < 70kW
EN 677: 1998 Condensing boilers < 70kW
EN 60335-2-102: 2006 Safety of household electrical products
EN 55014-1: 2006 EMC emissions of household equipment
EN 61000-3-2:2006 EMC limits for harmonic current emissions
EN 61000-3-3:2005 EMC limitation of voltage changes, voltage
fluctuations and flicker in public low-voltage supply
systems
EN 55014-2: 2001 EMC immunity of household equipment
1.2.1 Scope of certification
Products Covered NCM-1130HH 30kW
Gas Categories I2L(G25) , I2H(G20)
Gas Supply (G25)
Requires a governed gas supply at 20 mbar inlet pressure for
I
2H
(G20) and 25 mbar for I2L(G25)
Flue Types B23-B33-B53-C13-C33-C43-C53-C63-C83
1.3 Hazard
The appliance shall always be turned off by removing any heat demands.
Before working on the appliance ensures that the engine head temperature is below 150°C. This
is to prevent any uncontrolled engine start which would constitute a hazardous situation and/or
possible damage to the engine.
The engine head temperature can be found on the Fascia Controller, by following the procedure
below;
1. Press ‘OK’ button
2. Then press ‘I’ button (between 1 and 3 seconds)
3. Select ‘Engineer Level’ using the setting knob and press ‘OK’
4. Select ‘Input/Output test’ and press ‘OK’
5. Select ‘Head Control Temperature’ and read temperature from display and note value
6. Confirm head temperature by selecting ‘Head Limit Temperature’ and read temperature
from display and note value
7. Both readings should be within 50
°
C of each other
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1.4 Control of Substances Hazardous to Health
Note the following information on substances hazardous to health.
Adhesives and Sealants
The NCM-1130HH product employs a range of adhesives and sealants in its construction. These
substances are fully cured and give no known hazard in this state.
Insulation Pads, Fire Insulation
Refectory ceramic and ceramic fibre insulation is used in a number of places within the product.
These materials can cause irritation to skin, eyes and the respiratory tract.
If you have a history of skin complaints you may be susceptible to irritation. High dust levels are
usual only if the material is broken or handled.
In normal use of the product these materials are not accessible to the user and represent no
hazard. For servicing and maintenance operations likely to disturb the ceramic fibre parts, the
appropriate safety precautions should be taken before starting work.
If you do suffer irritation to the eyes or severe irritation to the skin, seek medical attention.
1.5 Maintenance and Servicing
Maintenance and servicing must only be carried out by KD NAVIEN trained persons. The product
will require regular maintenance and periodical inspection. It is the responsibility of the user to
ensure adequate access to the product by KD NAVIEN Service personnel to allow this
maintenance to take place in a timely manner.
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2.0 Technical Specifications
2.1 Performance data and General specifications
Specification Items Unit
NCM - 1130HH
Engine Burner Heat Input (Min-Max) kW 3.0-7.7
Supplmentary Burner Heat Input (Min-Max) kW 5.4-22.4
Both Burner Heat Input (Min-Max) (60/80℃)
kW 30.2
Both Burner Heat output (Max) (50/30℃)
kW 31.2
Both Burner Heat output (Max) (60/80℃)
kW 27.4
ELECTRICAL POWER kW 1.0
Useful Efficiency at Max Heating Output - Flow/Return (80/60℃)
% 97.4
Useful Efficiency at Max Heating Output - Flow/Return (50/30℃)
% 106.8
Useful Efficiency at 20% Max Heating Output – (Return 30℃)
% 107.0
NOx Class 5
Category I2L(G25) , I2H(G20)
Max Heating Water Pressure bar 3
Min Heating Water Pressure 0.8
Max Heating Temperature
℃
85
Adjustable Temperature Heating Setting
℃
30 – 85
Expansion Vessel Pre-charge bar 1
Electrical Supply V/Hz
230 / 50
Power Consumption W 116
Electrical Protection IPX4D
Intake/Exhaust Flue System Type
B23-B33-B53-C13-C33-C43-C53-
C63-C83
Intake/Exhaust Flue Diameter mm Concentric 60/100 – Separate 80/80
Connecting
Diameter
Heating Water Connection Inch
PT 3/4
Domestic Hot Water Connection Inch
PT 3/4
Gas Inlet Connection Inch
PT 3/4
Condendate connection mm
22
Physical dimensions (Width x Depth x Height) mm
480 x 430 x 1000
Weight kg 115
Table 1. Performance data and General specifications
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Diagram 2.1 Product dimensions
2.2 Minimum installation and service clearances
The product must not be installed in compartments or cupboards.
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2.3 Flue system specifications
2.3.1 Coaxial Horizontal flue systems.
The product is supplied complete with a concentric turret assembly and standard concentric
horizontal balanced flue terminal assembly suitable for flue lengths from 200mm to 10.5m (From
flue turret to flue terminal end)
Diagram 2.2 Flue through wall
Additional components are available to extend the length of the flue ducts. These components are
as follows:-
• 1000 mm straight concentric flue extension (Increases the length of flue by 960 mm).
• 500 mm straight concentric flue extension (Increases the length of flue by 460 mm).
• Air duct sealing collar (One required per joint).
• Flue weather proofing seal. (two per installation)
Extension ducts can be used to increase the straight flue length up to 10.5m, is measured
between the end of the flue terminal to the turret outlet.
When measuring up for maximum flue lengths, it is generally considered that a 900 elbow is the
equivalent to the frictional losses experienced on a 2m flue extension, for example if two 90
0
elbows are used in the flue run then the total straight flue run must not exceed 6.5m.
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2.3.2 Coaxial Vertical flue systems
The kit is supplied as a concentric flue assembly complete with terminal, suitable for heights of up
to 10.5m.
Diagram 2.3 Optional vertical flue systems available for use with the appliance
Vertical flue
Maximum length from the top of the
flue connector to the underside of the
terminal = 10.5m
Vertical flue using 2 x 45° bends
Note: 45° bends = 1 of a metre
resistance
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2.3.3 Separate flue systems
Diagram 2.4 Optional separate flue systems available for use with the appliance
Diameter of
Pipe [mm]
Max Flue
Length [m]
Reduced Flue Length [m]
Ø 80/100 10.5
45° 1.0
90° 2
Ø 80/80 20
45° 1.4
90° 3.5
Table 2. Reduction table
Total flue length:
A + B + C + D – (2 x 45° elbow) = 20 – 2
x 1.4 = 17.2 m
Total flue length:
A + B + C + D + E + F – ( 4 x 90° elbow)=
20 – 4 x 3.5 = 6.5 m
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2.4 KD NAVIEN appliance internals
Diagram 2.5 Product Internals
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3.0 Installation requirements
3.1 Statutory requirements
The installation of the product MUST be carried out by a competent person in accordance with
the relevant requirements of the current issue of:
• Manufacturers Instructions Supplied
• Gas Safety (Installation and use) regulations
• CORGI
• Current IEE Wiring Requirements for Electrical Installation (BS 7671)
• The Building Standards (Scotland) (Consolidation) Regulations,
• Water bylaws
• Water Supply (Water Fittings) Regulations
• The Health and Safety at Work, Act
• The Electricity at Work Regulations
• Any applicable local regulations
• EN 50438 Requirements for the connection of micro-generators in parallel with public
low-voltage distribution networks
•
UK
Engineering Recommendation G83/1 - for the connection of small-scale embedded
generators (SSEG) (up to 16A per phase) in parallel with public low-voltage distribution
networks.
Detailed recommendations are contained in the current issue of the following British Standards
and Codes of Practice.
• BS5449 Specification for forced circulation hot water central heating systems for
domestic premises
• BS5546 Specification for installation of hot water supplies for domestic purposes ,
using gas-fired products of rated input not exceeding 70 kW
• BS5440:1 Installation and maintenance of flues and ventilation for gas products of
rated input not exceeding 70 kW (1st, 2nd and 3rd family gases). Specification for
installation and maintenance of flues.
• BS5440:2 Installation of flues and ventilation for gas products of rated input not
exceeding 60kW. (1st, 2nd and 3rd family gases). Specification for installation of
ventilation for gas products.
• BS6798 Specification for installation of gas-fired boilers of rated input not
exceeding 70kW
• BS6891 Specification for installation of low pressure gas pipework of up to 28 mm
(R1) in domestic premises (2nd family gas)
• BS EN 4814
• BS EN 7074:1 Code of practice for domestic hot water supply
• BS EN 7074:2
• BS EN 7478
• BS EN 7593 Treatment of water in domestic hot water central heating systems
Manufacturer’s instructions must NOT be taken in any way as overriding statutory
obligations.
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3.2 Product position
The following limitations MUST be observed when sitting the product:
a) The product is not suitable for installation in timber-framed buildings or in rooms
containing a bath or shower.
b) The product is not suitable for installation in cupboards or compartments.
c) The product is not suitable for external installation.
d) This position MUST allow for supplied flue system and terminal position to be used. (Refer
to sections 2.3 and 3.3)
e) The product must be installed on a flat vertical wall, which is capable of supporting the
weight of the product and any ancillary equipment.
f) It is not necessary to provide an air vent in the room in which the KD NAVIEN product is
installed
g) Do not position the appliance above an area likely to be occupied by a kettle or toaster.
3.3 Flue terminal location
The following are notes:
a) The product MUST be installed so that the flue terminal is exposed to external air.
b) It is important that the position of the terminal allows free passage of air across it at all
times.
c) It is ESSENTIAL TO ENSURE 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.
d) The minimum acceptable dimensions from the terminal to obstructions and ventilation
openings are specified in Table 3 and Diagram 3.1
e) If the terminal discharges into a pathway or passageway check that combustion products
will not cause nuisance and that the terminal will not obstruct the passageway.
f) Should the lowest part of the terminal be fitted less than 2m above ground, a balcony, or
a flat roof to which people have access then a terminal guard is required. The terminal
guard specification should allow for the flue terminal to be entirely enclosed whilst
providing a clearance of 50mm between the body of the flue terminal and the terminal
guard casing.
Before installation commences, the suitability and strength of the wall on which the
product is to be mounted MUST be assessed by a competent person.
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g) Where a terminal is fitted less than 1m below a plastic gutter or less than 0.5m below
painted eaves or any other painted surface then a suitable shield at least 1m long shall be
fitted to protect the surface.
h) Noise and any discharge from the flue outlet must not cause a nuisance. Site flue
terminal in a suitable location.
i) Flue terminal must be sited so that it does cause obstructions e.g. pathways, driveways
j) Flue gases from this appliance have a tendency to plume. This could be a nuisance, for
example near security lighting. Site flue terminal in a suitable location.
k) The air inlet / flue outlet duct MUST NOT be closer than 25 mm to combustible material.
l) In certain weather conditions the terminal may emit a plume of water vapour. This is
normal but positions where this would cause a nuisance should be avoided.
Description
M
inimum
Distace
(cm)
A
From openings(e.g. doors, windows, ventilation tiles) 30(*1)
B
Below gullies, down-pipes, or drain pipes 7.5
C
Below gutters 20
D
Below balconies 20
E
From down pipes 2.5
F
From external and internal conrners 30
G
Above the ground, a roof or balconies 30
H
From the opposite wall of a carport(when another flue is
not installed)
60
I
From a terminal, that is facing the terminal, on the
opposite wall of a carport
120
J
Next to openings(e.g. doors, windows) within a carport 120
K
Vertically away from a terminal on the same wall 150
L
Horizontally away from a terminal on the same wall 30
M
From an addjacent vertical flue pipe 50
N
From openings is a directly opposing building 200(*2)
Table 3 Flue terminal Locations
Diagram 3.1: Acceptable terminal positions
For vertical flue pipes, the terminal must not be within 60 cm of any openings
Terminal guards must be provided for any terminals which are located less than 2
meters above a balcony, above a flat roof, or above ground which people can access.
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3.4 Central heating system
a) This product is designed for connection to open vented central heating water systems and
also for sealed systems up to 3 bar. Refer to Diagram 3.3 for a typical ‘open vented’
system design and to diagram 3.4 for a typical sealed system design.
b) The flow and return connections from the top of the unit PT 3.4” Male.
c) It is recommended that copper pipes are used for the flow and return for at least 2m from
the appliance.
d) It is recommended that the system is power flushed prior to the installation of the
appliance. Once the product has been installed, treat primary boiler circuit with a
suitable corrosion inhibiter such as, Sentinel X100 inhibitor.
e) It is strongly recommended to install a filter in the system.
f) It is recommended that an automatic air vented is installed on the system at the highest
point.
g) It is also recommended that, if not already installed on the heating system, an auto by-
pass shall be installed.
h) To help manage the level of operating noise of the installation it is recommended to
thoroughly purge air from the system, position pump in appropriate location, support pipe
work effectively, always firmly secure cover on casing.
The wall on which the intake/exhaust flue is set must be made of incombustible
interior materials and must connect to the outside. Dangerous materials or obstructions
must not be near the intake/exhaust flue.
The exhaust flue should be covered with over 20 mm of incombustible material when it
passes through a wall made of combustible material and must be kept at least 50 mm
away from any combustible materials.
Connection parts of the exhaust flue must be properly connected by proper sealing
gasket. Check for any exhaust gas leaks.
Before cleaning the intake/exhaust flue, turn off the appliance and wait until the pipes
have cooled down.
Safeguard the flue terminals from snow buildup.
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Diagram 3.2 Typical sealed system design.
The product can be connected to a sealed system. Ensure the manufactures instructions are
followed when connecting the product to the sealed system components. To appropriately size
the expansion vessel please use table 9a;
Safety Valve Setting (bar) 3.0
Vessel charge and initial system pressure (bar)
0.5 1.0 1.5
Total water content of system (litres) Vessel Volume
25 2.1 2.7 3.9
50 4.2 5.4 7.8
75 6.3 8.2 11.7
100 8.3 10.9 15.6
125 10.4 13.6 19.5
150 12.5 16.3 23.4
Table 4a: Expansion vessel table
5
5
3
2: Pressure
3: Auto
4: Double non return
5: Stop
7: Pump
6: Expansion
8: Air release
1: Pressure relief valve
2: Pressure gauge
3: Auto bypass
4: Filling point
5: Stop valve
6: Expansion vessel
7: Pump
8: Auto air release
8
6 4
7
1
2
Static head to top of product
Minimum 2 m
Maximum 30 m
Table 4: Static Head
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3.4.1 Hydraulic resistance
Diagram 3.3 Pressure Loss
3.4.2 Water treatment
The product incorporates a stainless steel heat exchanger.
Particularly where a new boiler is to be fitted to an existing system, it is good practice that the
system is thoroughly cleansed. This cleansing should take place prior to the fitting of the new
boiler and be in accordance with BS 7593.
In accordance with BS 7593 : 1992 a corrosion inhibitor such as Sentinel X100 should be used.
It is very important that the correct concentration of any additive is maintained at the level
recommended by the manufacturer. In hard water areas lime scale treatment may be necessary.
3.5 Gas supply
a) Consult the gas supplier before attempting to install the appliance
b) The gas installation must be in accordance with the current issue of BS 6891
c) A minimum of 22mm diameter pipework is required to within 1 metre of the product and a
pressure drop of no more than 1 millibar is permissible
c) Before any gas work commences, the gas pipework shall be tested for soundness.
Artificially softened water not be be used.
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d) The governor at the meter must give a constant outlet pressure of 25 mbar I2L(G25)and 20
mbar I2H(G20)
d) The gas supply line should be purged
e) The complete installation must be tested for gas soundness and paperwork completed.
3.6 Electricity supply
a) Wiring external to the product must be in accordance with BS 7671 for electrical
installation and any local regulations which apply.
b) The requirements of EN50438 and National Standards shall be followed.
c) The point of isolation of the product from the mains should be readily accessible to the
user.
3.7 Condensate drain
A plastic drain pipe(or drain hose which is contained in the appliance package) must be installed
to allow discharge of condensate to a drain.
Condensate should be discharged into the internal household draining system. If this is not
possible, external pipework is acceptable, see section 4.4 for more details.
Before purging open all doors and windows, also extinguish any cigarettes, pipes, and any
other naked lights.
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4.0 Installation Procedure
4.1 Unpacking
The product will come in a wooden package. Unpack and check the contents against the
Installation Preparation Checklist provided. A copy of which is shown overleaf
Any damage noticed to equipment shall be reported immediately to KD NAVIEN (82-2-
3489-2326)
The appliance may be damaged if it is not properly transported.
• Transport the appliance using the right transportation equipment, such as a hand truck
with a fastening belt or special equipment for maneuvering steps.
• Protect all parts against impact when they are transported.
• Observe the transportation markings on the packaging.
Packaged appliances must always be lifted and carried to their destination by two people,
or you must use a hand truck or special equipment to transport them to their destination.
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4.2 Preparing the wall for installation
The wall structure intended for the KD NAVIEN appliance must be of suitable construction, load
bearing and have a flat surface.
4.2.1 Fitting the wall mounting template.
1) Tape the paper template to the wall, ensure it is square.
2) Mark positions of four fixing holes as close as possible to the corners of the plate in the top
and bottom rows in secure positions on the wall, see diagram 4.1
3) Mark the position of the flue hole.
4) Remove the template from the wall.
5) Cut the flue hole, preferably with a core-boring tool.
6) It is absolutely essential that the KD NAVIEN appliance is installed vertically. If the wall is
bowed or not plum, then spacers must be inserted between the back plate and the wall such
that the back plate is accurately vertical.
If you are in doubt that the wall is capable of adequately supporting the weight of the
appliance and any ancillary equipment you MUST arrange for an assessment of structural
strength by a competent person. Stud / partition walls are NOT suitable
Ensure that during the cutting operation, masonry falling outside of the building does not
cause damage or personal injury.
Horizontal flue – Take into account a 3° slope downwards in the flue to the boiler.
Before installing the product, check that the chosen position is suitable (Section 3.0),
adequate installation clearances are available (Section 2.2) and that the requirements for
flue terminal position (Section 2.3), are satisfied.
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Diagram 4.1 Diagram showing cut away wall with m-CHP mounted
7) The Fischer Rawl bolts currently supplied by KD NAVIEN to secure the wall mounting bracket
to the wall must be used in all cases
8) Set drill stop at depth of 90mm
9) Drill an 8mm diameter hole into the wall, using rotary hammer drill in conjunction with SDS
drill bit.
10) Thoroughly clean the hole of dust and drill debris
11) Push the FUR 8X80 T frame fixing into the hole through wall mounting bracket and make
sure that the collar of the nylon plug is flush with wall mounting bracket.
12) Tighten the coach screw with T30 screw driver bit
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4.3 Mounting the appliance
4.3.1 Lifting Equipment
Before lifting work is processed, following requirement should be ensured.
1. Ensure that a visual inspection is carried out to asses for any obvious defects (such as
worn tyres, dents in equipment – noted by broken paintwork)
2. Check and remove any obstacles along the routes from where the appliance is, to where it
is to be installed.
3. Ensure all involved in the installation are aware that the lifting equipment is being used.
4. The height that the lifting kit raises the appliance must be kept to a minimum, only when
the back plate is ready should the appliance be raised on the lifting equipment.
5. Any house thresholds will need appropriate temporary ramps in place.
Lifting Equipment should comply with the following requirement.
- Weight allowed for lifting process should be at least + 200Kg
- The wheels must be locked during lifting process
- Ensure that balance is being sustained when carrying
4.3.1.1 Use of Lifting Gear
This process describes removing an NCM-1130HH appliance from a packaging box to the wall.
1) When you lift the appliance, do not get rid of the EPP bottom base.
2) Installation should be carried out by 2 people.
Carefully check the security of the wall mounting plate before proceeding further.
This step can be delayed until immediately prior to system commissioning if site security
cannot be guaranteed. If this option is required, isolate the service connections and
continue with the system installation procedure described in the following sections, then
return to this section later.
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4.4 Condensate Drain
Diagram 4.2 Condensate drain connection
The condensate drain connection is at the bottom of the product, see Diagram 4.2. Connect the
product condensate drain to the condensate drain hose which is contained in package box. The
condensate drain hose is 20mm internal diameter (22mm external diameter for any pipework
installed external to the property) and is made of a suitable acid resistant material.
The discharge pipe from the boiler condensate drain must have a continuous fall (45mm per
meter) away from the product and preferably be installed and terminated within the building to
prevent freezing.
The condensate discharge pipe must terminate in a suitable position, e.g.:
a) Preferably the condensate pipe should be run and terminate internally to the house soil
and vent stack (at least 450mm above the invert of the stack). A trap giving a water seal
of at least 75mm should be incorporated into the pipe run, and there must be an air break
in the discharge pipe upstream of the trap. This should be designed so that the
condensate cannot be discharged into the house if the condensate pipe becomes blocked.
b) Connecting into the internal discharge branch (e.g. sink waste or washing machine)
with an external termination, the condensate discharge pipe should have a minimum
diameter of 22mm with no length restriction and should incorporate a trap with a 75mm
seal. The connection should preferably be made down stream of the sink waste trap. If
the connection is only possible upstream, then an air break is needed between the two
traps. This is normally provided by the sink waste.
c) Terminating in a gully below grid level and above the water level. The external pipe
length should be kept a short as possible to minimize the risk of freezing and should not
be more than 3m.
f) At a condensate absorption point (soakaway). The external pipe length should not be
more than 3m
g) The disposal of condensate liquid must comply with local Water Authority rules and
regulations.
Condensate drain
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The diagrams below show acceptable means of condensate drain connection
If it is necessary to install any condensate discharge pipework externally, then it should be
kept as short as possible to a maximum length of 3m, be insulated with waterproof
insulation and have a continuous fall of a least 2.5° (i.e. 45mm for every metre length).
Diagram 4.2
a Internal termination of condensate drain to internal stack
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