Ravenheat WH 80/90 (T) INSTRUCTIONS FOR USE

THE WHITE BOILER COMPANY

Instructions for Use

Installation and Servicing

To be left with the user

COMBINATION BOILER

HIGH EFFICIENCY

CONDENSING

WH 80 (T)

Natural Gas (G20) I2H - II

LPG (G30-31) I2H - II

2H3+

G. C. No. 47-506-05

2H3+

G.C. No. 47-506-06

WH 90 (T)

Natural Gas (G20) I2H - II

LPG (G30-31) I2H - II

Technical and illustrative data are not binding and can be modiﬁ ed without prior notice. The descriptions and illustrations in the present booklet are for guidance purposes only.

THE WHITE BOILER COMPANY A Ravenheat Group Company CHARTISTS WAY, MORLEY, LEEDS, LS27 9ET TEL. 0113 252 7007 - FAX: 0113 238 0229

Website : www.ravenheat.co.uk - E-mail : sales@ravenheat.co.uk

2H3+

G. C. No. 47-506-07

2H3+

G.C. No. 47-506-08

1312

2

HIGH

EFFICIENCY CONDENSING BOILER

FOR CENTRAL HEATING AN

Gas valve.

- Variable head pump suitable for any type of central heating system.

- Burner with ﬂ ame stabiliser designed to operate under all thermal conditions.

- Unique

condensing heat exchanger

for high thermal ﬂ ue transfer from gases to water.

- Stainless steel plate heat exchanger for super high heat transfer to domestic hot water supply.

- Built in frost protection.

- Printed circuit board designed to connect to room stat and/or timer/frost stat.

- Aesthetically pleasing panels and controls.

- On/Off ball valves for shutting off gas, central heating and domestic hot water circuit.

- Safety relief valve (for safety discharge).

- Programmable 7 day module with digital display (time clock version only).

efﬁ ciency of thi

HAZARDOUS TO HEALTH

IMPORTANT

EFFICIENCY CONDENSING BOILER

FOR CENTRAL HEA TING AND DOMESTIC HOT WATER

This new highly efﬁ cient turbo-modulating boiler is designed to meet domestic hot water and central heating requirements at super high efﬁ ciency.

POSITION

The appliance is extremely versatile as it can be ﬁ tted in almost any room. The appliance is room sealed so there is no contact

between the combustion chamber and living accommodation. This guarantees maximum safety and efﬁ ciency. Each boiler has been designed and manufactured in our modern plant to exacting ISO 9001 discipline, all boilers carry full CE marking of approval. Technical sales and commercial services are available throughout the UK Mainland. This product is guaranteed by The White Boiler Company , Chartists W ay, Morley, LEEDS, LS27 9ET. Telephone No (01 13) 252 7007.

Guarantee is a full 12 months from date of purchase providing the appliance has been ﬁ tted in accordance with these instructions

and relevant codes of practice.

MAJOR COMPONENTS

-

- Variable head pump suitable for any type of central heating system.

- Burner with ﬂ ame stabiliser designed to operate under all thermal conditions.

- Unique

- Stainless steel plate heat exchanger for super high heat transfer to domestic hot water supply.

- Built in frost protection.

- Printed circuit board designed to connect to room stat and/or timer/frost stat.

- Aesthetically pleasing panels and controls.

- On/Off ball valves for shutting off gas, central heating and domestic hot water circuit.

- Safety relief valve (for safety discharge).

- Programmable 7 day module with digital display (time clock version only).

NOTE: Due to the high

terminal during operation.

It is the Users/Installers responsibility to ensure that the necessary personal protective clothing is worn when handling this appliance, and where applicable the pertinent parts that contain any materials that could be interpreted as being injurious to health and safety.

Gas valve.

condensing heat exchanger

COSHH - CONTROL OF SUBST ANCES

for high thermal ﬂ ue transfer from gases to water.

efﬁ ciency of this boiler a plume of water vapour will form at the ﬂ ue

HAZARDOUS TO HEAL TH

IMPORT ANT

GENERAL INFORMATION: GLUES AND SEALANTS - exercise caution - if these are still in liquid form. THE WHITE BOILER COMPANY use only high quality material for production of this product, in an effort to protect the environment wherever possible components should be recycled.

WARNING: when installing the appliance, care should be taken to avoid any possibility of injury when handling sheet metal parts.

3

Users instructions

Sections Page Sections Page

1 Users guide 6 5 Installation 25

1.1 Introduction 6 5.1 Warning 25

1.2 Clearances around the appliance 6 5.2 Delivery 25

1.3 Operating safety checks to protect 6 5.3 Unpacking of boiler 25 your appliance (checking the system 5.4 Positioning of the boiler 25 pressure) 5.5 Optional extras 26

1.4 Appliance status indicators 7 5.6 Plume management kit 27

1.5 Digital display 8 5.7 Installing the appliance for rear flue 28

1.6 Boiler value 8 outlet

1.7 Time 8 5.8 Installing the appliance for side flue 28

1.8 Programming the heating times 9 outlet

1.9 Diagnostic 9 5.9 Completing horizontal flue installation 31

5.10 Intake and exhaust terminal 31 components

2 General layout 10 5.11 In-line flue bend and flue extension 31

2.1 Operating scheme 11 5.12 Vertical flue instructions 32

2.2 Introduction 12 5.13 Installation instructions for twin flue 34

2.3 Description of control system and 12 pipe sequence of operation 5.14 Twin flue instructions 34

2.4 Domestic hot water mode 12 5.15 Exhaust / suction system with 35

2.5 Central heating mode 12 concentric pipes for flat or sloping

2.6 General function 12 roofs.

2.7 Overall dimension 13 Extensions with two separate pipes

2.8 Safety device 13 5.16 Exhaust / suction system with two 35

2.9 Available pump head 13 separate rated 80 dia. pipes

2.10 Pressure drop across appliance 13 exhaust on flat or sloping roof, suction from vertical wall

3 Technical data WH 80(T) natural gas 14 5.17 Exhaust / suction system with two 35

3.1 Technical data WH 80(T) LPG 15 separate pipes through a single

3.2 Technical data WH 90(T) natural gas 16 vertical wall

3.3 Technical data WH 90(T) LPG 17 5.18 Installation instructions for 80/125 36 concentric flue system

4 General requirements 18 5.19 Assemble boiler 37

4.1 Safety 18 5.20 Fitting valve pack 37

Gas safety (Installation and use) 5.21 Gas connection 37

4.2 General information 18 5.22 Central heating connection 37

4.3 Location of boiler 19 5.23 Domestic hot water connection 37

4.4 Clearances around the appliance 19 5.24 Position of water/gas connections 37

4.5 Important notice 19 5.25 Safety valve discharge 38

4.6 Gas supply 19 5.26 Condensate drain connection 38

4.7 Flue system 20 5.27 Converting the appliance to different 39

4.8 Air supply 20 gas types

4.9 Water circulation (central heating) 20 5.28 Electrical connections 39

4.10 Flue terminal position 21 5.29 Outdoor sensor 39

4.11 Pipework 22

4.12 Boiler interlock control 22 6 Commissioning 40

4.13 Draining tap 22 6.1 Gas supply installation 40

4.14 Air release points 23 6.2 Electrical installation 40

4.15 Mains water feed: central heating 23 6.3 Initial filling of the system 40

4.16 Permissible methods of filling 23 6.4 Setting the heating system 40

4.17 Sizing of additional expansion vessel 24 design pressure

4.18 Installation to an existing central 24 6.5 Filling the hot water system 40

heating system 6.6 Lighting the boiler 40

4.19 Water treatment 25 6.8 Check the gas pressure 41

4.20 Hard water areas 25 6.9 Combustion check 41

4.21 Domestic water 25 6.10 Checking the flue system 42

4.22 Electrical supply 25

4

Sections Page Sections Page

6.11 Checking the heating thermostat 42 11 Spare parts 55

6.12 Testing/regulating the D.H.W flow 42

6.13 Keep hot 42 12 Benchmark commissioning 60

6.14 C.H. high/low temperature 42 checklist details

6.15 Range rating central heating or/and 43 12.1 Analyser check list 65 domestic hot water

6.16 Test mode 43

6.17 Instructing the user 43

7 Servicing instructions 44

7.1 Boiler frost protection 44

7.2 To inspect and clean the appliance 45

8 Replacements of parts 45

8.1 General 45

8.2 To remove front panel 45

8.3 To remove left and right panels 46

8.4 To remove/replace spark igniter box 46

8.5 To remove/replace fan 46

8.6 To remove/replace the electrodes 47

8.7 To remove/replace the burner 47

8.8 To remove/replace the heat 47 exchanger

8.9 To remove/replace expansion 48 vessel

8.10 To remove/replace gas valve 48

8.11 To remove/replace plate heat 48 exchanger

8.12 To remove/replace the water 48 pressure transducer

8.13 To remove/replace diverter valve 49 motor

8.14 To remove/replace C.H. diverter 49 valve

8.15 To remove/replace D.H.W. diverter 49 valve mechanism

8.16 To remove/replace pump 49

8.17 To remove/replace automatic air vent 49

8.18 To remove/replace safety relief valve 50

8.19 To remove/replace D.H.W. sensor 50

8.20 To remove/replace C.H. flow and 50 return sensors

8.21 To remove/replace flue sensor 50

8.22 To clean and remove/replace 50 condensing trap

8.23 To remove panel control box 51

8.24 To remove the instrument panel 51

8.25 To remove/replace control board 51

8.26 To remove/replace digital display 51 board

8.27 External control connection 51

9 Fault finding Central heating 52

9.1 Fault finding Domestic Hot Water 53

10 Electrical system diagram 54

5

A minimum bottom clearance of 80 mm is

required between the appliance

USER CONTROLS

This appliance is designed to operate with the minimum of ease for the user. All the controls are found on the control panel on the front of the boiler.

1.3 OPERATING SAFETY CHECKS TO PROTECT YOUR APPLIANCE (CHECKING THE SYSTEM PRESSURE)

Before lighting the appliance check that the Central Heating system pressure is not less than 1 bar. If it is below this it will be necessary to re-pressurise the system, between 1 and 1.5 bar to allow the boiler to operate. To view the system pressure press the P button once, this will display the current pressure

(if the pressure is on nil or too low, then error code 08E is displayed).

A ﬁ lling device (ﬁ lling loop) will have been ﬁ tted on the system. This is usually on the pipework near to the boiler. If you are unsure of its position, or you cannot identify it, consult the installer who ﬁ tted the boiler. The ﬁ lling loop usually consists of two taps and a separate silver coloured braided ﬂ exible pipe with connection ﬁ ttings. Only when re-pressurising should the braided ﬂ exible pipe be connected between the two taps, ensure that the nuts or the pipe ends are tightened onto the taps. Fully open one of the taps ﬁ rst and then while monitoring the water pressure on the digital display, carefully open the second tap. When the water pressure is to a maximum of 1.5 bar turn both taps off. Disconnect the ﬂ exible pipe from the taps (a small amount of water may be present). Keep the pipe in a safe place for future use. Press the P button once to return to the main screen.

In the event of an error, the appliance will show a sequence code displayed on the digital display of the control panel (ﬁ g. 1). By pressing the “RESET“ button it is possible to relight the boiler (see page 51 for list of error codes).

1 USERS GUIDE

It is the law that all gas appliances are installed by a competent person, in accordance with the gas safety installation and to the current Gas Safety (Installation and Use) Regulations B.S.5440:2-(2000).

All registered installers carry a Gas Safe Register ID card and have a registration number. Both should be recorded in your boiler Log book. You can check your installer’s registration at www.gassaferegister.co.uk.

ESCAPE OF GAS Should a gas leak be suspected, contact your gas supplier without delay .

GAS EMERGENCY NUMBER: 08001 11999

Do NOT search for gas leaks with a naked ﬂ ame.

However, if the option is preferred to remove the

panels then a minimum clearance of 55mm is required.

Top clearance:

The top clearance should be a minimum of 125 mm.

Bottom clearance:

required between the appliance and any surface, though 150 mm is preferred whenever possible.

Front clearance: A minimum of 450 mm is required in front of the appliance for access during servicing, the front clearance can be reduced when installed in a cupboard to 25 mm from the access door.

of ease for the user. All the controls are found on the control panel on the front of the boiler.

WARNING: This appliance must be earthed.

1.1 INTRODUCTION Please carefully read the information given in this

booklet to help you gain maximum control from your appliance with minimum trouble and cost.

Y our White Boiler Company Condensing Low Nox combination boiler has been designed to supply your Central Heating and Domestic Hot Water directly from one unit. When Central Heating is operating, the circulation will be interrupted when Domestic Hot Water is being drawn off (domestic hot water has priority). This will normally not affect the level of Heating.

PLEASE NOTE:

Due to the high efﬁ ciency of this appliance and resulting

low ﬂ ue gas exhaust temperature a white plume of condensation vapour (cool steam) will be emitted from the ﬂ ue outlet terminal, this is quite normal. It will be particularly evident during periods of low outdoor temperature or when the boiler is working at its optimum performance (Plume Management kits are available on request).

IMPORT ANT: In the unlikely event of the exhaust ﬂ ue gases exceeding

the overheat temperature setting, the boiler operation will be stopped to prevent damage to the appliance.

1.2 CLEARANCES AROUND THE APPLIANCE

Side clearance:

The position of the appliance must provide a minimum clearance of only 5mm as the side panels do not require removing for servicing.

1.3 OPERA TING SAFETY CHECKS T O PROTECT YOUR APPLIANCE (CHECKING THE SYSTEM PRESSURE)

Heating system pressure is not less than 1 bar. If it is below this it will be necessary to re-pressurise the system, between 1 and 1.5 bar to allow the boiler to operate. To view the system pressure press the P button once, this will display the current pressure

pressure is on nil or too low, then error code 08E is displayed).

A ﬁ lling device (ﬁ lling loop) will have been ﬁ tted on the system. This is usually on the pipework near to the boiler . If you are unsure of its position, or you cannot identify it, consult the installer who ﬁ tted the boiler. The ﬁ lling loop usually consists of two taps and a separate silver coloured braided ﬂ exible pipe with connection ﬁ ttings. Only when re-pressurising should the braided ﬂ exible pipe be connected between the two taps, ensure that the nuts or the pipe ends are tightened onto the taps. Fully open one of the taps ﬁ rst and then while monitoring the water pressure on the digital display , carefully open the second tap. When the water pressure is to a maximum of 1.5 bar turn both taps off. Disconnect the ﬂ exible pipe from the taps (a small amount of water may be present). Keep the pipe in a safe place for future use. Press the P button once to return to the main screen.

sequence code displayed on the digital display of the control panel (ﬁ g. 1). By pressing the “RESET“ button it is possible to relight the boiler (see page 51 for list of error codes).

A minimum bottom clearance of 80 mm is

USER CONTROLS

This appliance is designed to operate with the minimum

Before lighting the appliance check that the Central

In the event of an error, the appliance will show a

(if the

6

1.4 APPLIANCE STATUS INDICATORS

maintain time and update parameters. The screen will display CLOW, after a few minutes of power su

Your boiler is equipped with a large LCD display that indicates the appliance operating status (ﬁ g. 1).

After a long period switched off (no power supply), the ﬁ rst switch on the internal backup circuit will charge in order to and update parameters. The screen will display CLOW, after a few minutes of power supply the display will be charged enough to allow all the functions.

maintain time

During the initial charge time, the display doesn’t allow the visualisation and/or modiﬁ cation function parameters. Instead other functions are working. When the appliance operates in rest mode, the display shows the boiler temperature and, for the time clock version only, the time. Alternatively the digital display also shows the water pressure.

KEY :

1 - ON/OFF button. Press to turn the boiler ON, “SUM” (hot water only) “WIN” (hot water and heating if set) and OFF. Press the button also to conﬁ rm selections.

2 - Press to reset the appliance if ever an error code is displayed.

3/4 - Temperature and function mode selectors. Press the arrow up or the arrow down to increase or decrease the heating or domestic hot water outlet temperature, when the digital display is in hot water or domestic set-point temperature. Press also to show the boiler values or to show the options program when the digital display is in menu setting.

5 - Press to set the Central Heating

Temperature required (when in winter mode).

Press the arrow up or the arrow down buttons to increase or decrease the temperature.

6 - Press to set the Domestic Hot Water

Temperature required. Press the arrow up or the arrow down buttons

to increase or decrease the temperature.

Fig. 1

7 - TIMER MODE (time clock version only). Press to select “Auto” (heating times set), “Manual” (heating on all the time) and off (heating off).

8 - Press to show the boiler values. Use the arrow up and arrow down buttons to select

the follows info: PBAR: water pressure

SFAN: speed fan (the display shows 3 digits (e.g. 500 = 5000 rpm) TFLOW: ﬂ ow temperature TRET: return temperature TDHW: domestic hot water temperature PWR: % power of modulation.

- Press 3 seconds to enter into menu. Use the arrow up or arrow down buttons to select the following options:

- TIME (time clock version only): It is possible to set the time and the current day (Monday 1, Tuesday 2, Wednesday 3, Thursday 4, Friday 5, Saturday 6, Sunday 7), see section 1.7.

- PTMR (only time clock version): Is possible to set the time clock, see section 1.8.

- BOIL: Is possible to set the boiler parameters C.H. max fan speed D.H.W. max fan speed Keep hot: “0” disabled and “1” enabled C.H. High/Low temperature: “1” high/“2” low.

7

Use the arrow up and the arrow down

buttons, (item 3 and

time clock

(time clock

1. Monday

2. Tuesday

3. Wednesday

4. Thursday

5. Friday

6. Saturday

7. Sunday 2 - Time (time clock version only). 3 - Central Heating: when the appliance is in central heating mode icon 3 will be ﬂ ashing. 4 - Auto (time clock version only): when the digital clock is in automatic function icon 4 is displayed. 5 - Water pressure: Shows the current pressure in the system. 6 - Manual: When the digital timer is set to manual icon 6 is displayed, in this mode the central heating is on permanently.

1.5 DIGITAL DISPLAY

time clock

KEY 1 - Day indicator:

(time clock version only)

1. Monday

2. Tuesday

3. Wednesday

4. Thursday

5. Friday

6. Saturday

7. Sunday 2 - Time (time clock version only). 3 - Central Heating: when the appliance is in central heating mode icon 3 will be ﬂ ashing. 4 - Auto (time clock version only): when the digital clock is in automatic function icon 4 is displayed. 5 - Water pressure: Shows the current pressure in the system. 6 - Manual: When the digital timer is set to manual icon 6 is displayed, in this mode the central heating is on permanently.

Fig. 2

7 - ON/OFF: When the appliance is ON icon 7 is displayed. 8 - Modulation ﬂ ame level: When the burner is lit, 3 different levels on icon 8 are displayed. 9 - Day function ( 10 - Temperature. 11 - Anomaly - Lock - out - Test function. 12 - Domestic hot water: when the appliance is in domestic hot water mode the icon will ﬂ ash.

time clock version only).

1.6 BOILER VALUE

It is possible to show the boiler value. Press P button to show the boiler value.

Use the arrow up and the arrow down buttons, (item 3 and 4 ﬁ g. 1) to show the following info:

PBAR: water pressure SFAN: speed fan TFlow: ﬂ ow temperature TRet: return temperature TDHW: domestic hot water temperature PWR: % power of modulation.

1.7 TIME ( SETTING THE TIME AND DAY

version only):

1. Press and hold the P button for 4 seconds.

2. Press the up and down arrows to select “TIME” and then press the enter button.

3. Press the up and down arrows to select the current hour (24h). Then press the enter button.

4. Press the up and down arrows to select the current minute and then press the enter button.

5. Press the up and down arrows to select the current day (1=Mon, 2= Tue etc.) and then press the enter button. The time is now set.

time clock version only)

(time clock

8

1.8 PROGRAMMING THE HEATING TIMES

time clock vers

For example, setting Mon-Sat

1.9 DIAGNOSTIC

The display shows eventual error or faulty message.

Stop boiler: The boiler stops the operating cycle and waits for the disappearance of the cause of the error in order to go back to be operating mode.

Block boiler: The boiler requires a manual reset to become operational again.

time clock version only)

(

The appliance incorporates a digital clock programmed with a default heating pattern (see table 1); however this can be modiﬁ ed to suit individual needs.

To change the programmed times:

1. Press and hold the P button for 4 seconds.

2. Press the up and down arrows to select

“P TMR” and then press the enter button.

3. Press the up and down arrows to select the

individual day you wish to set, or select the group of days (see table 2) then press the enter button.

4. Press the up and down arrows to select the

ON1 time (ﬁ rst on time) and press the enter button.

5. Press the up and down arrows to set the

OF1 time (ﬁ rst off) and press enter. Repeat this process for the remaining 3 settings. (Note: if not all 4 times are required then set the remaining on and off times to

24.00, this cancels the remaining on and off.

For example see the weekend settings in (table 1.)

Once the times are set, press the P button and this will return to the main screen.

NB: If setting the times in a group, the days in the group will all be the same, however days not in this group will remain at the default time.

For example, setting Mon-Sat will change all these days but Sunday will remain the same as table one unless changed individually.

The programmed times will only be activated when the boiler is in winter mode (section 1.4 key 1) and also set in auto mode (section 1.4 key 7). If you wish to override these times, press the timer mode button to select “MAN”, this puts the boiler in manual mode which overrides the timer on the boiler so the heating is on permanently (providing any external controls ﬁ tted are calling for heat). To turn the heating off, press the timer mode button to select off, this will now turn the heating off permanently until either auto or manual is selected.

TABLE 1

TABLE 2

1.9 DIAGNOSTIC

The display shows eventual error or faulty message.

Stop boiler: The boiler stops the operating cycle and waits for the disappearance of the cause of the error in order to go back to be operating mode.

Block boiler: The boiler requires a manual reset to become operational again.

9

2.0 GENERAL LAYOUT (Fig. 3)

KEY

1 - Condensate trap 2 - Gas valve 3 - Gas inlet 4 - Drain point 5 - CH ﬂ ow 6 - Diverter valve motor

7 - DHW outlet 8 - DHW sensor 9 - DHW flow detector 10 - DHW inlet 11 - Safety pressure relief valve

12-Water pressure transducer 13 - CH return 14 - Control board 1 5 - Circulation pump 16 - Automatic air vent 17 - Condensate drain 18 - Expansion vessel 19 - Main heat exchanger 20 - Spark electrode 21 - Sensing electrode 22 - Flue temperature sensor

Fig. 3

23 - Spark igniter 24 - Fan 25 - Burner 26 - Manual air vent 27 - Overheat cut off thermostat 28 - CH flow sensor 29 - CH return sensor

10

temperature

2.1 OPERATING SCHEME (Fig. 4)

KEY

1 - Flue exhaust manifold 2 - Condensate drain 3 - CH return 4 - CH return sensor 5 - Heat exchanger 6 - CH ﬂ ow 7 - Overheat cut off thermostat 8 - CH ﬂ ow sensor 9 - Manual air vent

10 - Burner 1 1 - Spark electrode 12 - Sensor electrode

13 - Fan 14 - Flue 15 - Expansion vessel 16 - Automatic air vent 17 - Circulation pump 18 - Water pressure transducer

temperature sensor

Fig. 4

19 - Safety pressure relief valve 20 - Diverter valve motor 21 - Plate heat exchanger 22 - DHW sensor 23 - Gas valve 24 - Gas service cock 25 - CH compression ball valves 26 - DHW compression ball valves

11

external timer if required. The

2.2 INTRODUCTION

It is possible to select either a summer or

winter function. With the summer position only being for domestic hot water. The winter position being for central heating

with domestic hot water priority.

2.3

DESCRIPTION OF CONTROL SYSTEM

AND SEQUENCE OF OPERATION

2.4 Domestic hot water mode

When the appliance is in rest mode, select the summer position by pressing the ON/OFF button (item 1 fig. 1) please ensure that the heating circuit is charged with water (above 1 bar). If the domestic hot water tap is turned on the boiler will function in the

following sequence:

The fan speed settings on the boiler increases

to the maximum permissible speed over a period of 5 seconds and will remain at its maximum required power until its maximum regulated temperature is achieved and then will modulate to maintain this.

When the domestic hot water tap is closed the

diverter valve goes back into rest mode, the burner is shut down along with the fan which is also switched off.

2.5 Central heating mode

If the appliance is in winter mode with a

demand for heat to supply radiators, etc. , with the heating circuit fully cha

This boiler is designed for the production of central heating and domestic hot water combined in one unit. It is ﬁ tted with an automatic domestic hot

water priority valve.

With the summer position only being for domestic hot water. The winter position being for central heating

2.3 AND SEQUENCE OF OPERA TION

2.4 Domestic hot water mode

When the appliance is in rest mode, select the summer position by pressing the ON/OFF button (item 1 fig. 1) please ensure that the heating circuit is charged with water (above 1 bar). If the domestic hot water tap is turned on the boiler will function in the

It is possible to select either a summer or

winter function.

with domestic hot water priority .

DESCRIPTION OF CONTROL SYSTEM

following sequence:

The pump starts. The fan starts and sends a signal back to the ignition board that the fan is running.

The spark ignition system is powered which in

turn commences the spark igniter to operate and light the burner.

At this point the ignition board opens the gas

valve to light the burner.

When the electrode sensor senses the signal

that the burner is alight, the spark igniter stops.

When the domestic hot water tap is closed the

2.5 Central heating mode

The fan speed settings on the boiler increases

to the maximum permissible speed over a period of 5 seconds and will remain at its maximum required power until its maximum regulated temperature is achieved and then will modulate to maintain this.

diverter valve goes back into rest mode, the burner is shut down along with the fan which is also switched off.

If the appliance is in winter mode with a

demand for heat to supply radiators, etc. , with the heating circuit fully charged above 1 bar, so as to operate the low water sensor device the boiler will start in the same way as domestic hot water mode.

As the heating sensor reaches temperature

the fan speed modulates to maintain the temperature set on the display panel. When starting, the fan will always start at the set-point speed.

The boiler is ﬁ tted with an anti-cycling device

on the control board. This delays the boiler

from re-ﬁ ring within 10 minutes. If the heating temperature goes 20°C below the set point, the burner restarts immediately . The domestic hot water will always take

priority and is unaffected by the anti-cycling

device.

2.6 GENERAL FUNCTION The instrument panel permits regulation of the

boiler to partial heating requirements, between

maximum and minimum settings. Air and gas are drawn by the fan for

combustion. The fan also forces exhaust gas through the ﬂ ue

to the outside, this creates a lesser pressure in

the sealed combustion chamber, thus sucking

in combustion air, through the inlet duct. The boiler water temperature is automatically

controlled by a built in thermostat. Interior space temperature is set by the room

thermostat to be installed in the heating

system. The boiler already carries connection

terminals for this thermostat, as well as for a

external timer if required. The burner continues

to operate until it is stopped by the digital clock

or one of the thermostats. When the internal C.H. temperature sensor

or the room thermostat intervenes the burner

shuts down. The fan stops but the pump

continues to operate for 3 minutes. The boiler also incorporates an anti-block

system which powers the pump every 24

hours, allowing it to operate for 2 minutes if

the boiler has not been in use. This operation

may in some cases be heard for a short period

when the pump has been activated. The heat exchanger in the D.H.W. circuit is

a stainless steel plate heat exchanger water

to water, and domestic water is heated by

converting the water in the central heating

circuit. The transfer of heat is very high

because the two ﬂ uids move in a counter

direction. Select the winter position by summer/winter

button (item 1 ﬁ g. 1).

12

When a hot water tap is turned on the diverter valve motor moves to exclude the central heating circuit, the boiler automatically modulates to maintain the domestic hot water at a constant temperature.

The water temperature can be regulated by

the digital display. When domestic hot water is being drawn off

the burner and pump perform as they do during central heating except that the burner is commanded by the D.H.W. thermostat.

When D.H.W. is no longer called for (tap is turned off), the boiler will automatically return to the central heating mode.

Select the summer position by pressing the

summer/winter button. The boiler functions like an automatic gas hot water heater. When D.H.W. is no longer required the burner and pump and fan will immediately turn off.

An overheat cut off thermostat acts to turn off the burner to resettable “lockout” (item 8 ﬁ g. 1).

The water temperature can be regulated by

When a hot water tap is turned on the diverter valve motor moves to exclude the central heating circuit, the boiler automatically modulates to maintain the domestic hot water at a constant temperature.

the digital display.

This also takes place when in winter mode, if there is no demand for heat to the central heating system or until the digital clock and room thermostat (if ﬁ tted) demands the central heating circuit.

2.8 SAFETY DEVICE

Select the summer position by pressing the

When domestic hot water is being drawn off the burner and pump perform as they do during central heating except that the burner is commanded by the D.H.W. thermostat.

When D.H.W. is no longer called for (tap is turned off), the boiler will automatically return to the central heating mode.

summer/winter button. The boiler functions like an automatic gas hot water heater. When D.H.W. is no longer required the burner and pump and fan will immediately turn off.

2.7 OVERALL DIMENSION (Fig. 5)

In both central heating and domestic hot

water mode safe operation is ensured by a

control board which shuts off the main

burner, if the fan stops or the ﬂ ue or combustion air intake duct is obstructed.

A safety valve is ﬁ tted on the central heating circuit set at 3 bar. A low water pressure switch set at 0.4 bar is

operating below this boiler system pressure.

An overheat cut off thermostat acts to turn off the burner to resettable “lockout” (item 8 ﬁ g. 1).

ﬁ tted on heating circuit, to prevent the boiler

Fig. 5

2.9 AVAILABLE PUMP HEAD (Fig. 6)

2.10 PRESSURE DROP ACROSS APPLIANCE (Fig. 7)

13

3 TECHNICAL DATA

WH 80 (T)

TABLE 3/A

NATURAL GAS (G 20) П2H3P

NOMINAL HEAT INPUT NET QMS 20.0 kW MINIMUM HEAT INPUT NET 3.7 kW

NOMINAL HEAT OUTPUT 19.5 kW NOMINAL HEAT OUTPUT CONDENSING 21.4 kW MINIMUM HEAT OUTPUT 3.6 kW MINIMUM HEAT OUTPUT CONDENSING 4.0 kW

GAS RATE max 2.1 m AFTER 10 MINUTES min 0.4 m3/h

INLET PRESSURE 20 mbar FAN SPEED Max 4200 rpm - 140 Hz Combustion % CO2 : 9.0 (+ 0.5 / - 0.5) Case ON

C.H. min 1300 rpm - 43 Hz 9.0 (+ 0.5 / - 0.5) Case OFF ELECTRICAL SUPPLY 230 V ~ 50 HZ

POWER CONSUMPTION 110 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265)

DRY WEIGHT 28 kg WATER CONTENT C.H. 0.8 litre WATER CONTENT 0.2 litre

3

/h

GAS SUPPLY CONNECTION 15 mm compression isolating valve FLOW CONNECTION C.H. 22 mm compression isolating valve RETURN CONNECTION C.H. 22 mm compression isolating valve INLET CONNECTION D.H.W. 15 mm compression isolating valve OUTLET CONNECTION D.H.W. 15 mm compression valve SAFETY DISCHARGE C.H. 15 mm copper pipe CONDENSATION DRAIN 3/4” (21.5 mm) push ﬁ t over ﬂ ow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C.H. MAX PRESSURE PHS 2.5 bar MINIMUM WORKING PRESSURE 0.5 bar 7 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar CENTRAL HEATING OPERATING TEMPERATURE MAX 80°C min 35°C DESIGN FLOW RATE 1383 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 350 I/h D.H.W. FLOW RATE 30 °C rise 11.9 l/min D.H.W. FLOW RATE 35 °C rise 10.2 l/min D.H.W. FLOW RATE 40 °C rise 8.9 l/min 10°C inlet temperature

D.H.W. TEMPERATURE Max 60 °C min 35 °C FAN SPEED D.H.W. Max 4800 rpm - 160 Hz min 1300 rpm - 43 Hz

Qmw Input Net Max 25.4 kW min 3.7 kW D.H.W. PRESSURE PMW Max 6.5 bar D.H.W. PRESSURE PMW min 0.5 bar D.H.W. MINIMUM FLOW RATE 2.5 I/min FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required) DESTINATION: GB, IE, ES, IT, PT & GR CATEGORY II FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

2H3P

A IP X4 D

14

3.1 TECHNICAL DATA

Combustion

WH 80 (T)

TABLE 3/B

LPG ( G 31) П2H3P

NOMINAL HEAT INPUT NET QMS 20.0 kW MINIMUM HEAT INPUT NET 3.7 kW

NOMINAL HEAT OUTPUT 19.5 kW NOMINAL HEAT OUTPUT CONDENSING 21.4 kW MINIMUM HEAT OUTPUT 3.6 kW MINIMUM HEAT OUTPUT CONDENSING 4.0 kW

GAS RATE max G31 0.8 m AFTER 10 MINUTES min 0.15 m3/h

INLET PRESSURE G31 37 mbar

3

/h

FAN SPEED C.H. Max 4200 rpm - 140 Hz

Combustion % CO2 : 10.5 (+ 0.5 / - 0.5) Case ON

min 1300 rpm - 43 Hz 10.5 (+ 0.5 / - 0.5) Case OFF ELECTRICAL SUPPLY 230 V ~ 50 HZ

POWER CONSUMPTION 110 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265)

DRY WEIGHT 28 kg WATER CONTENT C.H. 0.8 litre WATER CONTENT 0.2 litre

GAS SUPPLY CONNECTION 15 mm compression isolating valve FLOW CONNECTION C.H. 22 mm compression isolating valve RETURN CONNECTION C.H. 22 mm compression isolating valve INLET CONNECTION D.H.W. 15 mm compression isolating valve OUTLET CONNECTION D.H.W. 15 mm compression valve SAFETY DISCHARGE C.H. 15 mm copper pipe CONDENSATION DRAIN 3/4” (21.5 mm) push ﬁ t over ﬂ ow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C.H. MAX PRESSURE PHS 2.5 bar MINIMUM WORKING PRESSURE 0.5 bar 7 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar CENTRAL HEATING OPERATING TEMPERATURE MAX 80°C min 35°C DESIGN FLOW RATE 1383 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 350 I/h D.H.W. FLOW RATE 30 °C rise 11.9 l/min D.H.W. FLOW RATE 35 °C rise 10.2 l/min D.H.W. FLOW RATE 40 °C rise 8.9 l/min 10°C inlet temperature

D.H.W. TEMPERATURE Max 60 °C min 35 °C FAN SPEED D.H.W. Max 4800 rpm - 160 Hz min 1300 rpm - 43 Hz

Qmw Input Net Max 25.4 kW min 3.7 kW D.H.W. PRESSURE PMW Max 6.5 bar (147 p.s.i.) D.H.W. PRESSURE PMW min 0.5 bar (118 p.s.i.) D.H.W. MINIMUM FLOW RATE 2.5 I/min FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required) DESTINATION: GB, IE, ES, IT, PT & GR CATEGORY II

2H3P

FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

A IP X4 D

15

3.2 TECHNICAL DATA

TABLE 3/C WH 90 (T)

NATURAL GAS (G 20) П2H3P

NOMINAL HEAT INPUT NET QMS 24.5 kW MINIMUM HEAT INPUT NET 4.1 kW

NOMINAL HEAT OUTPUT 23.8 kW NOMINAL HEAT OUTPUT CONDENSING 26.2 kW MINIMUM HEAT OUTPUT 4.0 kW MINIMUM HEAT OUTPUT CONDENSING 4.4 kW

GAS RATE max 2.6 m AFTER 10 MINUTES min 0.4 m3/h

INLET PRESSURE 20 mbar FAN SPEED Max 4200 rpm - 140 Hz Combustion % CO2 : 9.0 (+ 0.5 / - 0.5) Case ON

C.H. min 1300 rpm - 43 Hz 9.0 (+ 0.5 / - 0.5) Case OFF ELECTRICAL SUPPLY 230 V ~ 50 HZ

POWER CONSUMPTION 119 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265)

DRY WEIGHT 29 kg WATER CONTENT C.H. 0.8 litre WATER CONTENT 0.2 litre

3

/h

GAS SUPPLY CONNECTION 15 mm compression isolating valve FLOW CONNECTION C.H. 22 mm compression isolating valve RETURN CONNECTION C.H. 22 mm compression isolating valve INLET CONNECTION D.H.W. 15 mm compression isolating valve OUTLET CONNECTION D.H.W. 15 mm compression valve SAFETY DISCHARGE C.H. 15 mm copper pipe CONDENSATION DRAIN 3/4” (21.5 mm) push ﬁ t over ﬂ ow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C.H. MAX PRESSURE PHS 2.5 bar MINIMUM WORKING PRESSURE 0.5 bar 7 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar CENTRAL HEATING OPERATING TEMPERATURE MAX 80°C min 35°C DESIGN FLOW RATE 1811 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 350 I/h D.H.W. FLOW RATE 30 °C rise 14.0 l/min D.H.W. FLOW RATE 35 °C rise 12.0 l/min D.H.W. FLOW RATE 40 °C rise 10.5 l/min 10°C inlet temperature

D.H.W. TEMPERATURE Max 60 °C min 35 °C FAN SPEED D.H.W. Max 4800 rpm - 160 Hz min 1300 rpm - 43 Hz

Qmw Input Net Max 30.1 kW min 4.1 kW D.H.W. PRESSURE PMW Max 6.5 bar D.H.W. PRESSURE PMW min 0.5 bar D.H.W. MINIMUM FLOW RATE 2.5 I/min FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required) DESTINATION: GB, IE, ES, IT, PT & GR CATEGORY II FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

2H3P

A IP X4 D

16

3.3 TECHNICAL DATA

TABLE 3/D WH 90 (T)

LPG (G 31) П2H3P

NOMINAL HEAT INPUT NET QMS 24.5 kW MINIMUM HEAT INPUT NET 4.1 kW

NOMINAL HEAT OUTPUT 23.8 kW NOMINAL HEAT OUTPUT CONDENSING 26.2 kW MINIMUM HEAT OUTPUT 4.0 kW MINIMUM HEAT OUTPUT CONDENSING 4.4 kW

GAS RATE max G31 1.0 m AFTER 10 MINUTES min 0.16 m3/h

INLET PRESSURE G31 37 mbar G30 28-30 mbar FAN SPEED C.H. Max 4200 rpm - 140 Hz Combustion % CO2 : 10.5 (+ 0.5 / - 0.5) Case ON

min 1300 rpm - 43 Hz 10.5 (+ 0.5 / - 0.5) Case OFF ELECTRICAL SUPPLY 230 V ~ 50 HZ

POWER CONSUMPTION 119 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 - 3.15 A (20 mm to BS 4265)

DRY WEIGHT 29 kg WATER CONTENT C.H. 0.8 litre WATER CONTENT 0.2 litre

3

/h

GAS SUPPLY CONNECTION 15 mm compression isolating valve FLOW CONNECTION C.H. 22 mm compression isolating valve RETURN CONNECTION C.H. 22 mm compression isolating valve INLET CONNECTION D.H.W. 15 mm compression isolating valve OUTLET CONNECTION D.H.W. 15 mm compression valve SAFETY DISCHARGE C.H. 15 mm copper pipe CONDENSATION DRAIN 3/4” (21.5 mm) push ﬁ t over ﬂ ow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C.H. MAX PRESSURE PHS 2.5 bar MINIMUM WORKING PRESSURE 0.5 bar 7 LITRES EXPANSION VESSEL PRE-CHARGE-PRESSURE 0.5 bar CENTRAL HEATING OPERATING TEMPERATURE MAX 80°C min 35°C DESIGN FLOW RATE 1811 I/h 20 °C RISE MINIMUM FLOW RATE C.H. 350 I/h D.H.W. FLOW RATE 30 °C rise 14.0 l/min D.H.W. FLOW RATE 35 °C rise 12.0 l/min D.H.W. FLOW RATE 40 °C rise 10.5 l/min 10°C inlet temperature

D.H.W. TEMPERATURE Max 60 °C min 35 °C FAN SPEED D.H.W. Max 4800 rpm - 160 Hz min 1300 rpm - 43 Hz

Qmw Input Net Max 30.1 kW min 4.1 kW D.H.W. PRESSURE PMW Max 6.5 bar D.H.W. PRESSURE PMW min 0.5 bar D.H.W. MINIMUM FLOW RATE 2.5 I/min FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required) DESTINATION: GB, IE, ES, IT, PT & GR CATEGORY II FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

2H3P

A IP X4 D

17

valuable

additional information:

equipment

4 GENERAL REQUIREMENTS

The installation of the boiler MUST be in accordance with the latest I.E.E. (BS 7671) Wiring Regulations, local building regulations,

Both the user and the manufacturer rely

heavily on the installer, whose job it is to

install the combination boiler and connect it to a correctly designed heating system. Acquaint yourself with the relevant British Standards concerning installation requirements. If you need further advice on any points contact the Technical Services Office on 0113 2527007 who would be pleased to help. It is recommended that tools suitable for brass fittings are used, and have a capability to accommodate hexagon sizes up to 50 mm.

4.1 SAFETY

Gas Safety (Installation and Use).

Regulations.

It is law that all gas appliances are installed

and serviced by a Gas Safe registered installer in accordance with the above regulations and these installation instructions. All registered installers carry a Gas Safe I.D. card and have a registration number. Both should be recorded in your Benchmark commissioning checklist. You can check your installer on the Gas Safe register (www.gassaferegister.co.uk). Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of your safety, to ensure the law is complied with. Check the boiler and flue is the correct type for installation undertaken.

4.2 GENERAL INFORMATION

heavily on the installer, whose job it is to

APPLICIBLE CODES OF PRACTICE Ref: Documents.

Detailed recommendations are contained in the

The installation of the boiler MUST 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.

Both the user and the manufacturer rely install the combination boiler and connect

it to a correctly designed heating system. Acquaint yourself with the relevant British Standards concerning installation requirements. If you need further advice on any points contact the Technical Services Office on 0113 2527007 who would be pleased to help. It is recommended that tools suitable for brass fittings are used, and have a capability to accommodate hexagon sizes up to 50 mm.

following British Standard Codes of Practice:

BS6891:2005: Low pressure installation

pipes. BS6798: Installation of gas fired hot water

boilers of rated input not exceeding 70 kW.

BS5546: Installation of gas hot water supplies domestic purposes

(2nd Family Gases).

BS5440: Flues (for gas appliances of rated

input not exceeding 70 kW).

BS5440: 2 Ventilation (for gas appliances of

rated input not exceeding 70 kW).

BSEN 677: 1998 Gas fired central heating boilers.

I.S. 813: Domestic gas Installations. The followings standards give

additional information: BS 7074: Expansion vessels and ancillary

equipment for sealed water system. BS 7593: Treatment of water in domestic hot water and central heating system.

Health & Safety Document No.635

The Electricity at Work Regulations, 1989.

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 this appliance unless covered by these Installation and Service Instructions or as otherwise recommended by The White Boiler Company in writing. If in doubt please enquire.

Any direct connection of a control device not

approved by The White Boiler Company could invalidate the certification and the normal appliance warranty.

It could also infringe the Gas Safety regulations

and the above regulations.

NOTE: The White Boiler Company WH 80/90 (T)

combi boiler has been tested and examined by CERTIGAZ, and is certified to comply with PrEN 483 and BS EN 625.

Manufacturers instructions must NOT be taken

in any way as overriding statutory obligations.

If in doubt on any point please consult The

White Boiler Company.

valuable

18

BSEN12828: Design for water based heating systems.

BSEN12831: Heating systems in buildings, Method for calculation of the design heat load.

BSEN14336: Installation & commissioning of water based heating systems.

4.3 LOCATION OF BOILER

The White Boiler Company WH 80/90 (T) combi boiler m

responsibility of the Gas Installer to size the gas installation pipework in accordance with BS 6891:2005. Whilst the principle of the 1:1 gas valve ensures t White Heat range

Siting of The White Boiler Company WH 80/90

(T) combi boiler must be as follows.

The position of installation should be within the

building, unless otherwise protected by a suitable enclosure.

Adequate space for installation, servicing and air circulation around the boiler must be allowed

for.

The appliance may be fitted on a combustible

For electrical safety reasons there must be no access available from the back of the boiler.

The boiler must not be fitted outside. LPG versions of this appliance shall not be

4.4 CLEARANCES AROUND THE APPLIANCE

Side clearance:

The position of the appliance must provide a minimum clearance of 5mm as the side panels do not require removing for servicing. However, if the option is preferred to remove the panels then a minimum clearance of 55mm is required.

Top clearance: The top clearance should be a minimum of 125 mm.

Bottom clearance: A bottom clearance of 80 mm is required

between the appliance and any surface. Though 150 mm is preferred whenever possible.

Front clearance: A minimum of 450 mm is required in front of the appliance for access during servicing, the front clearance can be reduced when installed in a cupboard, to 25 mm from the access door.

4.5 IMPORTANT NOTICE For installation into timber framed buildings,

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. Wiring Regulations, and in Scotland the electrical provisions of the Building Regulations

The White Boiler Company WH 80/90 (T) combi boiler must be fitted on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment.

wall and insulation between the wall and the boiler is not necessary, unless required by the local authority.

installed in cellars or basements.

please refer to the Institute of Gas Engineers Document IGE/UP/7.

applicable in Scotland, with respect to the installation of the combination boiler in a room or internal space containing a bath or shower.

Where a room sealed appliance is installed in a room containing a bath or shower, any electrical switch or appliance control, utilising mains electricity should be situated so that it cannot be touched by a person using a bath or shower. A compartment when used to enclose the combination boiler MUST be designed and constructed specifically for this purpose. An existing cupboard, or compartment, may be used provided it is modified accordingly Samples of the WH 80/90 (T) combi boiler have been examined by CERTIGAZ notification body, and are certified to comply with the essential requirements of the gas appliance.

Directive 90/396/EEC, the Low Voltage. Directive 72/23/EEC and shows compliance

with the Electro Magnetic Compatibility.

Directive 89/336/EEC and are therefore permitted to carry the CE Mark.

The appliance has been tested and approved

by the WRc as meeting the requirements of G3 and L of the Building regulations and water Bylaws Scheme - Approved Products.

4.6 GAS SUPPLY A gas meter is connected to the service pipe

by the Local Gas Region or the Local Gas Region contractor. An existing meter should be checked preferably by the Gas Region to ensure that the meter is adequate to deal with the rate of gas supply required for all appliances it serves. Installation pipes should be fitted in accordance with BS 6891:2005. Pipework from the meter to the boiler must be of adequate size (22 mm) min to within at least one metre of the boiler, (15 mm) min. can then be used for remaining pipe work to the appliance. A smaller size than the boiler inlet gas connection should not be used. The complete installation must be tested for soundness as described in the above code.

. N.B. It is the

to size the gas installation pipework in accordance with BS 6891:2005. Whilst the principle of the 1:1 gas valve ensures the White Heat range is able to deliver the full output at an inlet pressures as low as 14 mbar, other gas appliances in the property may not be as tolerant.

When operating pressures are found to be

below the minimum meter outlet of 19 mbar these should be checked to ensure this is adequate for correct and safe operation.

responsibility of the Gas Installer

19

Allowing for the acceptable pressure loss of 1

d at its

ocated in a place where it is likely to cause a nuisance in cold and/or humid weather as water vapour may condense on leaving the flue terminal.

The effect of such pluming must be

considered.

The terminal must not be closer than 25 mm (1 inch) to any combustible material for

less than 2 meters high

PRO110100.

Fit only recommended

FLUE TERMINAL

GUARD

times.

mbar across the installation pipework, it can be assumed that a minimum permitted operating pressure of 18 mbar will be delivered to the inlet of the appliance. (reference BS 6400-1 Clause 6.2 Pressure Absorption).

The external gas cock could further reduce the

operating pressure when measure point. The pressure drop is relative to the heat input to the boiler (kW), refer to graph below.

d at its test

IMPORTANT NOTICE: If the ﬂ ue terminates

below a balcony, above the ground, above a ﬂ at roof to which people have access, then a suitable terminal guard must be ﬁ tted if

less than 2 meters high

Fit only recommended

GUARD bby securing concentrically around

terminal with screws. Available on request from:

The White Boiler Company Chartists Way, Morley, Leeds, West Yorkshire ENGLAND LS27 9ET - UK

Tel. 0113 252 7007

IMPORTANT:

The following notes are intended for general guidance. The boiler MUST be installed so that the terminal is exposed to external air.

It is important that the position of the terminal allows the free passage of air across it at all times.

PRO110100.

FLUE TERMINAL

4.7 FLUE SYSTEM The terminal should be located where dispersal

of combustion products is not impeded and with due regard for the damage or discolouration that might occur to building products in the vicinity (section 4.10).

The terminal must not be l

where it is likely to cause a nuisance in cold and/or humid weather as water vapour may condense on leaving the flue terminal.

The effect of such pluming must be

considered.

The terminal must not be closer than 25 mm (1 inch) to any combustible material for protection of combustibles, refer to BS 5440.1. Where a flue terminal is installed less than

1000 mm. from a plastic, or painted gutter; or 500 mm from painted eaves, an aluminium shield 1000 mm. long, should be fitted to the underside of the gutter or painted surface.

Pluming will occur at the terminal so, where

possible, terminal positions which could cause a nuisance should be avoided.

The flue must be installed in accordance with

the recommendations of BS 5440: Part 1.

IMPORTANT NOTES: For greater ﬂ ue lengths see alternative ﬂ ue instructions. Flue must be positioned in a place not likely to cause a nuisance from pluming.

ocated in a place

Minimum acceptable spacing from the terminal to obstructions and ventilation openings are speciﬁ ed in section 4.10.

Note positions: Due to the terminal design, installation is possible with clearances less than those speciﬁ ed in BS 5440, Part 1

NOTE: The flue must be terminated in a place not likely to cause a nuisance.

A concentric vertical flue kit is available for

longer flueing applications (see table 5 page

26).

For further details see vertical flue installation

instructions.

4.8 AIR SUPPLY The following notes are intended for general

guidance.

The room sealed fan flued boiler does not

require a permanent air vent for combustion air supply.

Where installed in a cupboard or compartment

ventilation is not required.

4.9 WATER CIRCULATION (Central heating) Detailed recommendations are given in BS6798

2009/5449:1990 - BSEN12828 - BSEN12831

- BSEN14336 (for smallbore and microbore central heating systems). The following notes are given for general guidance.

20

4.10 FLUE TERMINAL POSITION

21

and aluminium

4.11 PIPEWORK

to ensure air is carried naturally to air release

points and water flows naturally to drain taps. It should be ensured as far as possible that the appliance’ s heat exchanger is not a natural collecting point for air except where providing useful heat. Pipes should be insulated to prevent heat loss and to avoid freezing. Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors.

IMPORTANT:

4.12 BOILER INTERLOCK CONTROL

Copper tubing to BSEN 1057:1 2006, BSEN 1172, BSEN 1652 and BSEN 1653, is recommended for water pipes. Jointing should be either with capillary soldered or with compression fittings. Where possible pipes should have a gradient

IMPORTANT: A minimum length of 1 metre of copper pipe

MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping.

The water through the appliance heat exchanger

If the volume of circulating water is too low, the

This appliance is designed to work on a two

to ensure air is carried naturally to air release

points and water flows naturally to drain taps. It should be ensured as far as possible that the appliance’ s heat exchanger is not a natural collecting point for air except where providing useful heat. Pipes should be insulated to prevent heat loss and to avoid freezing. Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors.

circuit must exceed the min. 2.38 gals/min. (650 It/h) when the burner is firing. It is important to ensure that this rate is achieved when sections of the system are shut off either manually or by automatic controls.

boiler water temperature will rise too rapidly. This could cause noise in the system or even cause the safety thermostat to trip.

pipe system as shown in fig.6.

Central heating systems controls should be installed to ensure the boiler is switched off

when there is no demand for heating, in

compliance with Building Regulations. The boiler has its own built in bypass. If the system has thermostatic radiator valves on

all radiators, or two port valves, then a bypass

circuit must be fitted with an automatic bypass

valve to ensure a flow of water should all valves

be in the closed position (fig. 6). It is important that the system is flushed

thoroughly before the appliance is fitted or

left to operate (as recommended in BS 7593)

in order to maintain an efficiently operating

heating system. For replacement installations,

the system MUST be flushed with the old boiler

in situ, in order to prevent system debris. Once

the system has been flushed, an inhibitor (suitable for stainless steel exchanger) should be added (see section

4.18).

4.13 DRAINING TAP These must be located in accessible positions

to permit the draining of the whole system.

The taps must be at least 15 mm nominal size

and manufactured in accordance with BS 2870

1980.

and aluminium heat

22

Fig.6

4.14 AIR RELEASE POINTS

7 Its of expansion water

If the appliance is connected to a system with

an unusually high water content, calculate the total expansion (see table 4) and add additional sealed expansion capacity as appropriate (Fig. 7). In general, modern systems below 7 lts should not present any problem.

4.15

MAINS WATER FEED. CENTRAL HEATING

There must be no direct connection to the

mains water supply, even through a

non-return valve, without the approval of the

Local Water Authority.

These must be fitted at all high points where

air will naturally collect, and must be sited to facilitate complete filling of the system.

The appliance has an integral sealed expansion

vessel to accommodate the increase of water volume when the system is heated.

It can accept up to If the appliance is connected to a system with

an unusually high water content, calculate the total expansion (see table 4) and add additional sealed expansion capacity as appropriate (Fig. 7). In general, modern systems below 7 lts should not present any problem.

4.15

There must be no direct connection to the non-return valve, without the approval of the

MAINS WATER FEED. CENTRAL HEATING

mains water supply, even through a Local Water Authority.

7 Its of expansion water

Fig.7

4.16 PERMISSIBLE METHODS OF FILLING Figure depicts the requirements of Diagram

R24.2a of the Water Supply (Water Fittings) regulations 1999.

Fig.8

23

If the capacity of the central heating system should exceed 110 Litres, an additional vessel should be installed on the return to the combination boiler from the heating system (fig. 7). Guidance on vessel sizing is given (see table 4).

Reference should be made to British Gas

Publications.

Debris from the system can damage the

boiler and reduce the efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance guarantee and contravene the Building Regulations.

It is recommended that you fit a primary water cleanser to the system. We recommend fitting a filter that will help remove both magnetite and non-magnetic debris.

4.17 SIZING OF ADDITIONAL EXPANSION VESSEL TABLE 4

Deduct from the value given in the table the 7 litre vessel supplied.

Safety

valve setting (bar)

Vessel charge

pressure (bar)

Initial system

pressure (bar)

T otal water

content of system

Litres

25 50

75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450 475 500

3.0

0.5 1.0 1.5

0.5 1.0 1.5 2.0 1.0 1.5 2.0 1.5 2.0

EXPANSION VESSEL VOLUME (LITRES)

2.1

4.2

6.3

8.3

10.4

12.5

14.6

16.7

18.7

20.8

22.9

25.0

27.0

29.1 31 .2

33.3

35.4

37.5

39.6

41.6

3.5

7.0

10.5

14.0

17.5

21.0

24.5

28.0 31 .5

35.0

38.5

42.0

45.5

49.0

52.5

56.0

59.5

63.0

66.5

70.0

6.5

12.9

19.4

25.9

32.4

38.8

45.3 51 .8

58.3

64.7 71 .2

77.7

84.1

90.6 97 .1

103.6

110.1

116.5

123.0

125.9

13.7

27.5

41.3

55.1

68.9

82.6

96.4

110.2

124.0

137.7 151 .5

165.3 179 .1

192.8

206.6

220.4

239.2

247.9

261 .7

275.5

2.7

5.4

8.2

10.9

13.6

16.3

19.1

21.8

24.5

27.2

30.0

32.7

35.7 38 .1

40.9

43.6

46.3

49.0 51 .8

54.5

4.7

9.5

14.2

19.0

23.7

28.5

33.2

38.0

42.7

47.5

52..2

57.0 61 .7

66.5 71 .2

76.0

80.7

85.5

90.2

95.0

10.3

20.6

30.9

41.2

51.5

61.8

72.1

82.4

92.7

103.0

113.3

123.6

133.9

144.2

154.5

164.8

175.1

185.4

195.7

206.0

3.9

7.8

11.7

15.6

19.5

23.4 27 .3

31.2 35 .1

39.0

42.9

46.8

50.7

54.6

58.5

62.4

66.3

70.2

74.1

78.0

107.6

115.8

124.1

132.4

140.7

148.9

157.2

165.5

8.3

16.5

24.8

33.1

41.3

49.6

57.9

66.2

74.5

82.7

91.0

99.3

For system volumes other than those given above, multiply the system volume by the factor across

Note: This pressure can be increased up to 1.5 bar to suit high static head situations.

0.0833 0.140 0.259 0.551 0 .109 0.190 0.412 0.156 0.331

.

Reference should be made to British Gas

4.18 INSTALLATION TO AN EXISTING CENTRAL

If the capacity of the central heating system should exceed 110 Litres, an additional vessel should be installed on the return to the combination boiler from the heating system (fig. 7). Guidance on vessel sizing is given (see table 4).

Publications. Draining taps should be at least 1/2” in BSP nominal size and be in accordance with BS 2879.

HEATING SYSTEM

BS 7593:2006 details the steps necessary to clean domestic central heating system. Also check pipework and renew any corroded pipework or fittings. Valve glands must be repacked or replaced wherever necessary and any defective controls exchanged.

boiler and reduce the efficiency. Failure to comply with the guidelines for the use of water treatment with the appliance will invalidate the appliance guarantee and contravene the Building Regulations.

The combination boiler is designed to operate

on a sealed system only. Therefore if the existing system is of the open water type it will have to be modified to comply with BS 5376 Part 2.

Before installing a new combination boiler to

water cleanser to the system. We recommend fitting a filter that will help remove both magnetite and non-magnetic debris.

an existing system, flush out the old system with a recommended descaling agent. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleaning, and flushing out the old system with recommended descaling agent.

24

Debris from the system can damage the

It is recommended that you fit a primary

4.19 WATER TREATMENT

manufacturer’s

instructions.

4.20 HARD WATER AREAS

If the area of installation is recognised as a hard water area, it is recommended that a suitable water treatment device is installed on the mains supply.

with a connection to a 230 V ~ 50 Hz single phase supply.

The supply must be fused at 3 A.

NOTE: The method of connection to the electricity supply MUST facilitate complete electrical isolation of the appliance, by the use of a fused, double pole isolator, having a contact separation of at least 3 mm in all poles. The point of connection to the electricity supply must be readily accessible and

The appliance carton contains:

a) Boiler fully assembled with ﬂ ue adaptor b) Installation instructions, user instructions and Benchmark log book c) White paper template d) Guarantee card e) Polythene bag containing:

-

1-15 mm gas service valve

- 2-22 mm compression ball valves

complete with 3/4” washers

- 1-15 mm compression ball valves complete with 1/2” washers

- 1- 15 mm compression ball valve

- 2 ﬁ xing bolts and wall plugs

5 INSTALLATION

This boiler has an aluminium and stainless steel

heat exchanger, The White Boiler Company recommend the use of FERNOX or SENTINEL, or other treatment products recognised by The White Boiler Company which must be used in accordance with the instructions.

4.20 HARD WATER AREAS

a hard water area, it is recommended that a suitable water treatment device is installed on the mains supply. The water hardness can be

4.21 DOMESTIC WATER The domestic hot water must be in accordance

4.22 ELECTRICAL SUPPLY

Warning: this appliance must be earthed

External wiring to the appliance must be carried out by a competent person and be in accordance with the current I.E.E. Regulations and local regulations which apply. The White Boiler Company boiler is supplied connection to a 230 V ~ 50 Hz single phase supply.

If the area of installation is recognised as

determined by using the standard test paper or by referring to local water authority.

with the relevant recommendations of BS 5546. Copper tubing to BS 2871-1 is recommended for water carrying pipework and MUST be used for pipework carrying potable water.

The supply must be fused at 3 A.

manufacturer’s

with a

5.1 WARNING It is MOST IMPORTANT that this appliance is

installed in a HORIZONTAL POSITION, with the flue air duct passing through the wall.

Make sure the flue is at a 1.5° incline, rising

from the boiler with 50 mm. Flue terminal diagram states 1.5° - 25 mm, fall back on flue (fig. 9).

5.2 DELIVERY

b) Installation instructions, user instructions and Benchmark log book c) White paper template d) Guarantee card e) Polythene bag containing:

-

complete with 3/4” washers

- 1-15 mm compression ball valves complete with 1/2” washers

- 1- 15 mm compression ball valve

- 2 ﬁ xing bolts and wall plugs

IMPORTANT NOTES:

The appliance carton contains:

a) Boiler fully assembled with ﬂ ue adaptor

1-15 mm gas service valve

- 2-22 mm compression ball valves

This appliance will produce a plume of

condensation in cool weather. This is due to the High Efﬁ ciency and hence low ﬂ ue gas temperature of the boiler. A plume management kit is available. (see section 5.6 ﬁ g 12)

5.3 UNPACKING OF BOILER

Fig.9

NOTE: The method of connection to the electricity supply MUST facilitate complete electrical isolation of the appliance, by the use of a fused, double pole isolator, having a contact separation of at least 3 mm in all poles. The point of connection to the electricity supply must be readily accessible and adjacent to the appliance except, where the appliance is installed in a bathroom.

The current electrical IEE Wiring regulations must be followed in GB.

IMPORTANT: With regard to the Manual Handling

Operations, 1992 Regulations, the following lift operation exceeds the recommended weight for a one man lift.

- Stand the boiler carton upright.

- Open the top of the carton.

- Rest the carton on the ﬂ oor (keeping the ﬂ aps open).

- Turn the carton over with the boiler inside and then pull the carton up away from the boiler.

- Rest the boiler on its back on the ﬂ oor to prepare it for installation.

5.4 POSITIONING OF THE BOILER Unscrew the two lower screws that secure the

front panel and pull forward and lift up (fig. 39).

Unscrew the 4 screws that fasten the lower

grating on the casing and remove it from the

bottom of the casing. Make sure the casing and screws are put to

one side in a safe place.

25

(horizontal length) (horizontal length)

ﬂ ue, the maximum

ﬂ ue length is 8 metres

5.5 OPTIONAL EXTRAS

HORIZONTAL FLUE KIT BOX CONTAINING (Fig 10):

57 - Elbow header 59 - Rubber seal Ø 60

56 - Rubber seal Ø 100 60 - Fumes sample point 61 - Flue exhaust duct 62 - Air intake duct 69 - Air sample point 127 - Terminal Rubber wall seal

IMPORTANT: Please, lubricate the internal part of the seals before fitting.

Generally speaking, oils and greases are not suitable for the “peroxide -EPDM”, therefore we suggest a correct lubrication using silicon-substances, for instance “Silikon Spray“ (Arexons).

Fig 10

FLUE EXTENSION BOX CONTAINING (Fig. 11): 1000 mm ﬂ ue extension duct as an extra cost only when requested for side and vertical ﬂ ue applications.

59 - Rubber seal Ø 60 63 - Air intake duct extension

64 - Flue exhaust duct extension

WARNING: With horizontal concentric ﬂ ue length is 8 metres, duct extension can be used with the standard ﬂ ue (see table 5).

ﬂ ue, the maximum

Fig 11

TYPE OF FLUE SYSTEM (All types) - minimum and maximum distance TABLE 5

Flue type C

13

C33 C

53

1

Flue Diameter 60/100 80/125 60/100 80/125 80mm (concentric) (concentric) (concentric) (concentric) single pipe

Minimum length (m) 0.3 0.3 1.0 1.0 0.5 Maximum length (m) 8.0 23.0 13.0 26.0 43.0

(horizontal length) (horizontal length) (vertical length) (vertical length)

Equivalent length of 45° bend (m) 0.5 1.25 0.5 1.25 1.25 Equivalent length of 90° bend (m) 1.0 2.5 1.0 2.5 2.5

26

5.6 PLUME MANAGEMENT KIT (Fig 12)

Max 6000 mm ﬂ ue extension duct as an extra cost only when requested to reduce pluming nuisance of condensation from 60/100 horizontal concentric ﬂ ue.

Plume Management Kit TABLE 6

Maximum Length (mm) 6000 minimum length (mm) 500

Equivalent length of 45° bend (mm) 500 Equivalent length of 90° bend (mm) 1000

The Maximum permitted ﬂ ue length is measured from the centre line of the ﬂ ue terminal to the top of the outlet terminal

IMPORTANT : Max ﬂ ue length must not exceed 6 m with a horizontal concentric 60/100 ﬂ ue of 3 m ( L )

Plume Management Kit Part No. Part. No. Description

TER110101 1 metre high plume kit containing: (Fig. 12) n. 1 terminal bend n. 1 90° elbow bend n. 2 45° bend n. 1 metre 60 M-F ﬂ ue length n. 1 ﬂ ue length bracket

FLUE EXHAUST DEFLECTION BEND (Fig 12a)

Flue exhaust deﬂ ection bend are also available. These come in both 45° and 90° degree versions. These bends ﬁ t directly onto the ﬂ ue exhaust terminal to deﬂ ect the ﬂ ue gas plume in an upward or sideways direction. Although they are not substitute for a plume kit, they can be considered useful where condensate pluming is causing a nuisance or can be used to eliminate condensate collecting on the end of the horizontal ﬂ ue terminal.

Fig. 12

CUR110050 45° ﬂ ue exhaust deﬂ ection bend (Fig. 12a)

CUR110100 90° ﬂ ue exhaust deﬂ ection bend (Fig. 12a)

IMPORTANT: Please, lubricate the internal part of the seals before fitting.

L+L max 6000 mm minimum plume kit length 500 mm

Fig. 12a

27

5.7 INSTALLING THE APPLIANCE FOR REAR

Mark the two holes for the top fixing bolts to fix the boiler on the wall as well as the centre of the flue duct.

- Detach the template from the wall.

- Use a 10 mm. dia drill to make the 2 holes. Insert the plastic expansion plugs.

- Cut or core drill a 105 mm dia hole for

inserting the flue duct. Fit the elbow header into the flue flange on

the top of the boiler, positioning it towards the required direction (fig 13).

Important: Make sure that the dia 60 mm on the elbow header is inserted fully into the flue manifold, and the flue manifold rubber seal is correctly fitted. (Fig 17 item

65)

If using the horizontal flue duct and it is too long it can be shortened. Should it be necessary to cut the flue always cut on right angles and ensure the cut is de-burred.

Note

: Add 30 mm to overall flue length to

allow for terminal wall cover.( fig.10 item 127).

Insert the flue assembly into the wall.

Lift the boiler on the wall, locating onto the top two fixing bolts. Tighten the two bolts using a spanner to secure to the wall.

Working above the boiler pull the flue exhaust

duct towards the boiler in order to engage tube

(fig. 18 item 61) into its header.

Position flue into elbow header and push so as

to locate inner and outer flue correctly ensuring a good seal is made with O-rings. Tighten the two screws on the flue flange to secure the elbow header in place.

Fit the terminal rubber wall seal and if

necessary terminal guard.

Extension kits are available to order for flue extension of up to a total overall length of 8 metres (fig.18).

Each extension length extends the pipe by

approximately 1000 mm long up to a maximum of seven extensions.

Extensions must be installed with the widened

end of the air intake pipe and the tapered end of the flue pipe aimed towards the exhaust terminal.

g.14.

- Mark the two fixing bolt securing holes on the wall and extend the axis of the flue duct hole to the side wall ensuring it i

fixing bolts.

In

FLUE OUTLET (Fig. 13, 16, 17, 18). FOR APPLIANCE CLEARANCES SEE SECT. 4.4 AND SECT. 4.10

Extensions must be installed with the widened

end of the air intake pipe and the tapered end of the flue pipe aimed towards the exhaust terminal.

Use adhesive tape to attach the template to the wall, making sure that the centre line is vertical and that the clearance distance is no less than that shown in fig. 13.

- fix the boiler on the wall as well as the centre of the flue duct.

Important: Make sure that the dia 60 mm on the elbow header is inserted fully into the flue manifold, and the flue manifold rubber seal is correctly fitted. (Fig 17 item

65)

If using the horizontal flue duct and it is too long it can be shortened. Should it be necessary to cut the flue always cut on right angles and ensure the cut is de-burred.

allow for terminal wall cover.( fig.10 item 127).

Lift the boiler on the wall, locating onto the top two fixing bolts. Tighten the two bolts using a spanner to secure to the wall.

duct towards the boiler in order to engage tube Position flue into elbow header and push so as

necessary terminal guard.

extension of up to a total overall length of 8 metres (fig.18).

Mark the two holes for the top fixing bolts to

- Detach the template from the wall.

- Use a 10 mm. dia drill to make the 2 holes. Insert the plastic expansion plugs.

- Cut or core drill a 105 mm dia hole for

inserting the flue duct. Fit the elbow header into the flue flange on

the top of the boiler, positioning it towards the required direction (fig 13).

Note

: Add 30 mm to overall flue length to

Insert the flue assembly into the wall.

Working above the boiler pull the flue exhaust

(fig. 18 item 61) into its header. to locate inner and outer flue correctly ensuring

a good seal is made with O-rings. Tighten the two screws on the flue flange to secure the elbow header in place.

Fit the terminal rubber wall seal and if

Extension kits are available to order for flue

IMPORTANT: Inline flue bend - 1000 mm must be deducted f rom overall length for each 90°bend. Obtuse flue bend - 500 mm must be deducted from overall length for each 135° bend (see table 5).

5.8 INSTALLING THE APPLIANCE FOR SIDE FLUE OUTLET (Fig. 14, 15, 16, 17, 18)

- Attach the template to the wall with adhesive tape, making sure that the centre line is

vertical and that the distance from the centre line to the nearest side wall is not less than measurement in fi

- Mark the two fixing bolt securing holes on the wall and extend the axis of the flue duct hole to the side wall ensuring it is horizontal.

- Make sure flue slopes 1.5° down towards

the boiler and that there is a 25 mm fall per metre of the flue length.

- Trace the centre of the flue duct hole and measure distance from the corner of the wall (fig.14), measure the distance (127 mm) between the centre of flue duct hole to the corner.

Detach the template from wall.

-

Use a 10 mm. dia drill to make the 2 holes for

fixing bolts.

the plugs. Core drill a 105 mm side wall for inserting the flue duct.

Fit the elbow header into the flue flange on the top of the boiler, positioning it towards the required direction.

Important: Make sure that the dia 60 mm on the elbow header is inserted fully into the flue manifold, and the flue manifold rubber seal is correctly fitted. (Fig 17 item 65).

If using the horizontal flue duct and it is too long it can be shortened.

Should it be necessary to cut the flue always cut on right angles and ensure the cut is de-burred.

Note: Add 30 mm to overall flue length to allow for terminal rubber wall seal ( fig.10 item 127).

g.14.

Insert the plastic expansion

dia. hole in the

Each extension length extends the pipe by

approximately 1000 mm long up to a maximum of seven extensions.

28

REAR FLUE OUTLET

Lift the boiler on the wall, locating onto the two fixing bolts. Tighten the two bolts using a spanner to secure to the wall.

Working above the boiler pull the flue duct towards the elbow in order to engage the tube into its header (fig.10). Position the flue elbow in line with the flue and push so as to locate inner and outer flue correctly. Ensuring a good seal is made with O-rings. Tighten the two screws on the flue flange to secure the elbow header in place.

IMPORTANT:

Terminal rubber wall seal must be fitted (item 127 fig.10).

Each extension length extends the pipe

by approximately 1000 mm long up to a maximum of seven extensions.

Pipeline length can be established using the

instructions in section 5.5. Extensions must be installed with the widened end of the air intake pipe and the tapered end of the flue pipe aimed towards the exhaust terminal.

Extensions must be joined together with the standard terminal pipe, and inserted in each other as far as they can go.

If an extension must be shortened, this must

be done from the straight end, and not from the widened or tapered end. To measure the pipeline properly all components must be assembled and total length measured before cutting. The straight end of the extension connects to the boiler. The flue output and air intake pipes fits into the boiler header until it stops (fig.17 - 18).

When cutting both inner and outer ducts of

the extension, always ensure that the reduced end (male) of the inner and outer duct are square and to the same length.

NOTE: minimum side clearances of 5mm as the side panels do not require removing for servicing. However, if the option is preferred to remove the panels then a minimum clearance of 55mm is required.

The position of the appliance must provide

Fig 13

Insert the flue assembly into the wall, making

sure it will not interfere when fixing the boiler on the wall.

towards the elbow in order to engage the tube into its header (fig.10). Position the flue elbow in line with the flue and push so as to locate inner and outer flue correctly. Ensuring a good seal is made with O-rings. Tighten the two screws on the flue flange to secure the elbow header in place.

Terminal rubber wall seal must be fitted (item 127 fig.10).

Pipeline length can be established using the

Lift the boiler on the wall, locating onto the two fixing bolts. Tighten the two bolts using a spanner to secure to the wall.

Working above the boiler pull the flue duct

IMPORTANT:

Each extension length extends the pipe

by approximately 1000 mm long up to a maximum of seven extensions.

instructions in section 5.5. Extensions must be installed with the widened end of the air intake pipe and the tapered end of the flue pipe aimed towards the exhaust terminal.

If an extension must be shortened, this must

When cutting both inner and outer ducts of

Extensions must be joined together with the standard terminal pipe, and inserted in each other as far as they can go.

be done from the straight end, and not from the widened or tapered end. To measure the pipeline properly all components must be assembled and total length measured before cutting. The straight end of the extension connects to the boiler. The flue output and air intake pipes fits into the boiler header until it stops (fig.17 - 18).

the extension, always ensure that the reduced end (male) of the inner and outer duct are square and to the same length.

29

SIDE FLUE OUTLET

All joints must be sealed with the rubber seals

supplied.

It is important to put the centering spacer, supplied

with the unit, inside between the two pipes, from the side opposite the extension’s straight end.

NOTE: minimum side clearances of 5mm as the side panels do not require removing for servicing. However, if the option is preferred to remove the panels then a minimum clearance of 55mm is required.

Fig. 14

The position of the appliance must provide

NOTE: A suitable support bracket (flue bracket)

is available from The White Boiler Company and should be used to support the flue length at least every one metre preferably at each joint this bracket should be secured to wall and flue duct.

Fig. 15

30

50 - Flue ﬂ ange

5.9 COMPLETING HORIZONTAL FLUE INSTALLATION.

Ensure the flue system has been checked for

soundness, is stable and secure. Where the horizontal flue terminal passes through the external wall, it is essential that the flue must be sealed on both in exterior and interior part of the wall.

The terminal rubber must also be fitted (fig. 16-17 item 127).

5.10 INTAKE AND EXHAUST TERMINAL COMPONENTS

Fig 16

Fig.17

KEY

50 - Flue ﬂ ange 56 - Rubber seal Ø 100 57 - Elbow header 58 - Header gasket 59 - Rubber seal Ø 60

5.11 IN-LINE FLUE BEND AND FLUE EXTENSION

IN-LINE FLUE BEND Measure the distance between the flue bends or

the flue/terminal assembly. The measurements should be taken from the outer edge of the flue and bend (fig. 18).

60 - Fumes sample point

61 - STD ﬂ ue exhaust duct 62 - Terminal 63 - Flue extension 64 - Flue exhaust duct extension

IMPORTANT: Please, lubricate the internal part of the seals before fitting.

65 - Flue manifold rubber seal 66 - Securing screw

67 - Flue temperature sensor 69 - Air sample point 127 - Terminal Rubber wall seal

49 - In-line Flue Bend 56 - Rubber seal Ø 100 59 - Rubber seal Ø 60 63 - Air intake duct extension 64 - Flue exhaust duct extension

Fig.18

31

5.12 VERTICAL FLUE INSTRUCTION ONLY (Fig. 19-20-21)

permissible flue

length is not exceeded (fig. 20 and see table 5).

- Mark the two wall fixing bolt holes

- Detach the template from the wall.

- Use a 10 mm dia. drill to make the 2 holes.

- Insert plastic expansion plug.

- Screw in the two coach bolts.

- Position the flue sample point starter (straight flue header which must be fitted) and fix the securing screw on the flue adaptor appliance

SEE SECT. 4.10 FOR PERMISSIBLE FLUE POSITION

IN-LINE FLUE BEND - 1000 mm MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 90° BEND OBTUSE FLUE BEND -500 mm MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 135° BEND.

The vertical flue kit is intended for use where a horizontal flue outlet is not possible or desired. The vertical flue can be used either with a flat roof or a pitched roof (maximum pitch 60°). Where a straight vertical flue is not possible or desired, an offset vertical flue can be used in conjunction with a side horizontal flue extension piece and in-line 135°/90° flue bend (fig. 19).

IMPORTANT NOTES : For greater flue length see twin flue or concentric 80/125 flue instructions

Proceed with installation as detailed in section 5 ignoring all references to horizontal flue installations. Use adhesive tape to attach the template to the wall, making sure that the centre line is vertical and that the flue centre line is virtually below the point at which the flue will exit the roof.

L + L = 8m Max

Fig. 19

32

Fig. 20

Straight Flue Straight Flue Offset Flue Offset Flue L = 12.0 m Max L = 12.0 m Max L = 10 m Max L = 11 m Max plus Terminal plus Terminal plus 2 bend 90° plus 2 bend 45° and Terminal and Terminal

- Ensure that the maximum length is not exceeded (fig. 20 and see table 5).

- Mark the two wall fixing bolt holes

- Detach the template from the wall.

- Use a 10 mm dia. drill to make the 2 holes.

- Insert plastic expansion plug.

- Screw in the two coach bolts.

- Position the flue sample point starter (straight

flue header which must be fitted) and fix the securing screw on the flue adaptor appliance

permissible flue

(fig. 22 item 66), and ensure that the gasket

is correctly fitted.

Important: Make sure that the dia 60 mm

on the straight flue header is inserted fully into the flue manifold, and the flue manifold rubber seal is correctly fitted. (Fig 22 item 65)

Cut a 105 mm diameter hole through the ceiling and/or

the

roof, at the point previously marked. Fit a roof flashing slate to the roof, available from The White Boiler Company. Insert the Vertical Flue terminal assembly through the flashing slate from the outside. Lift the boiler on the wall, locating onto the top two fixing bolts. Tighten the two bolts using a spanner to secure to the wall. Measure the vertical distance between the top of the flue and the bottom of the flue terminal assembly (fig.

21). The measurements should be taken from the outer diameter of the flue. NOTE: Where this length does not match any standard combination of the extensions, only be cut to the required length (fig. 23). When cutting both inner and outer ducts of the extension, always cut on spigot side, and they must be de-burred.

ACCESSORIES CONCENTRIC FLUE 60/100 EXTRAS: TABLE 7

the extension can

Part. No. Description PR5094110A Straight ﬂ ue header / sample point

60/100 PRFE Flue Extension 60/100 L1000 PR45FBI 45° bend 60/100 PR90FBI 90° Elbow bend 60/100 PR5023016 Horizontal terminal 60/100 TER110200 Vertical ﬂ ue Terminal

Starting at the appliance end, assemble the extension duct sections, making each inner and outer (flue) joint by inserting the spigot end into the socket end of the next tube, making sure the seal rings are correctly located (fig. 22). Make sure that the entire flue is adequately supported. Use at least one bracket for each extension used. Ensure that all inner flue connections have a good fit/seal, and that the space clips in each extension are correctly positioned.

Fig.22

Fig. 21

Straight Flue Offset Flue Offset Flue L = 12.0 m Max L = 12 m Max L = 11 m Max plus Combi ridge plus 2 bend 90° plus 2 bend 45° and Combi ridge and Combi ridge

Fig.23

KEY

56 - Flue adapter 58 - Header gasket 59 - Rubber seal Ø 60 60 - Fumes sample point 63 - Flue extension 64 - Flue exhaust duct extension 65 - Flue manifold rubber seal 66 - Securing screw 68 - Flue starter 69 - Air sample point

IMPORTANT: Please, lubricate the internal part of the seals before fitting.

33

5.13 INSTALLATION INSTRUCTIONS FOR TWIN FLUE PIPE (ECCENTRIC FLUE DUCT SYSTEM)

Make sure that the ﬂ ue manifold rubber seal is located into the ﬂ ue manifold, and lubricate the internal part of the seal before assembly. Locate the header gasket on the twin ﬂ ue header and push into the ﬂ ue adaptor making sure that the inner plastic exhaust

TABLE 8

Part. No Description SDO110050 Twin ﬂ ue header F80/F80

PRO110200 Straight pipe L.1000 80 CUR110150 90° elbow bend 80 CUR110200 45° bend 80 GRI110050 Air inlet terminal 80 GRI110100 Exhaust terminal 80 TER060110 Vertical eccentric ﬂ ue Terminal

5.14 TWIN FLUE INSTRUCTIONS This part of the installation manual covers the

installation and ﬁ xing instructions of the twin ﬂ ue eccentric ﬂ ue duct systems only. When ordering twin ﬂ ue it must be stated for WH 80/90 (T) range. Typical installation procedures are illustrated by drawings.

Remove the front panel of the case (sect.8.1). Unscrew the screw (item 66 ﬁ g. 17) on the ﬂ ue adapter .

Fig. 24

IMPORTANT: Please, lubricate the internal part of the seals before fitting.

IMPORTANT: These instructions must be read in

conjunction with the main installation and servicing instructions. As with all ﬂ ues the kits must be installed taking due account of the current issue of BS 5440 parts 1 & 2 and timber frame housing DM2 is referenced to the Institute of Gas Engineers Document IGE/UP/7. Also note that the requirements will vary depending upon the kit being installed. Guidance is provided but unless otherwise stated, always comply with the recommendations of the relevant codes of practice.

Make sure that the ﬂ ue manifold rubber seal is located into the ﬂ ue manifold, and lubricate the internal part of the seal before assembly. Locate the header gasket on the twin ﬂ ue header and push into the ﬂ ue adaptor making sure that the inner plastic exhaust locates ﬁ rmly in the outlet spigot of the ﬂ ue manifold, and screw the securing screw that secure the

twin ﬂ ue header on the boiler. Locate the 2 x 80 mm O-rings in the twin flue header and lubricate the internal part of the seal before assembly to ensure easy snug ﬁ t.

Figures show the versatility of this flueing

system. Measurements and bends must be

calculated correctly so as not to oversize

maximum flue lengths.

All located O-rings must be lubricated with a

silicone grease to ensure a snug fit.

NOTE: Exhaust flue must slope 1.5° down

towards the boiler 25 mm/m fall per metre of

flue length.

Spacing Clips

Spacing Clips are available on request should

they be required.

NOTE: for eccentric vertical flue a 125 mm

(5 in) diameter flashing plate will be required.

34

IMPORTANT:

See ﬁ g. 6 for terminal clearances.

Chartists way, Morley, Leeds, West Yorkshire

See ﬁ g. 6 for terminal clearances.

-

IMPORTANT NOTICE:

- Inlet and exhaust terminals must never be installed on opposite walls of the building (PrEN 483).

- If the ﬂ ue terminates less than 2 m above a balcony, above

the ground, or above a ﬂ at roof to which people have access, then a suitable terminal guard must be ﬁ tted.

- Fit only recommended ﬂ ue terminal guard by securing concentrically around terminal with screws.

Fig. 25

5.15

Exhaust/suction system with concentric pipes for ﬂ at or sloping roofs. Extensions with two separate pipes (ﬁ g. 24).

Maximum distance: T = L = 21 + 21 = 42 metre + Terminal Minimum distance: L = 0.5 + 0.5 = 1metre + Terminal

Exhaust terminal must not be cut.

NOTE:

- If bends are used in the exhaust ﬂ ue then horizontal

- Sections must be avoided and there must be a 1.5° slope

- Towards the boiler 25 mm fall per metre.

5.16

Maximum distance D = L + L1 = 39.5 metre + Terminal Minimum total length = 2 metre NOTE: Exhaust ﬂ ue must slope 1.5° down towards the boiler 25 mm fall per metre.

Fig. 26

IMPORTANT: Please, lubricate the internal part of the seals before fitting.

Exhaust/suction system with two separate

5.17 pipes through a single vertical wall (ﬁ g. 26).

Maximum distance: D = L + L1 = 37 metre Minimum distance: D = L + L1 = 1 metre Min distance between pipe 50 mm.

Available on request from: THE WHITE BOILER COMPANY

Chartists way, Morley, Leeds, West Yorkshire ENGLAND LS27 9ET - U.K. Tel. 0113 252 7007

35

installed on either a flat roof or a pitched roof (maximum pitch 60°). Where a straight vertical flue is not possible or desired, an offset vertical flue can be used in conjunction with a side horizontal flue extension piece and an inline 135°/90° flue bend (fig. 27).

See ﬁ g. 6 for terminal clearances.

Available on request from: THE WHITE BOILER COMPANY Chartists way, Morley, Leeds, West Yorkshire ENGLAND LS27 9ET - U.K. Tel. 0113 252 7007

5.18 INSTALLATION INSTRUCTIONS FOR CONCENTRIC 80/125 FLUE SYSTEM

The vertical 80/125 flue kit is intended for use

where a horizontal 60/100 flue outlet is not possible or desired. The vertical flue can be roof or a pitched roof (maximum pitch 60°). Where a straight vertical flue is not possible or desired, an offset vertical flue can be used in conjunction with a side horizontal flue extension piece and an inline 135°/90° flue bend (fig. 27).

IMPORTANT:

See ﬁ g. 6 for terminal clearances.

-

IMPORTANT NOTICE: When using our vertical ﬂ ue kit the 125 mm x 100 reducer is supplied complete with the vertical terminal simply remove this and ﬁ x it into the straight ﬂ ue header (which must be ﬁ tted) on the top of the boiler.

installed on either a flat

Fig. 27

L + L = 23.5m Max

Fig. 28

Straight Flue Straight Flue 90° Offset Flue 135° Offset Flue L = 25 m Max L = 25 m Max L = 20 m Max L = 22.5 m Max plus Terminal plus Terminal plus Terminal plus Terminal

NOTE : If using Flue arrangement in ﬁ g. 27 then the 125x100 Flue reducer

TABLE 9

Part No Description PR5094110A Straight ﬂ ue header / sample point 60/100

must be purchased separately.

IMPORTANT: Please, lubricate the internal part of the seals before fitting.

PRO110300 Flue Extension 80/125 L1000 RID110050 125/80 to 100/60 Flue reducer CUR110250 45° ﬂ ue bend 80/125 CUR110300 90° elbow ﬂ ue bend 80/125 TER010050 Horizontal Flue Terminal 80/125 TER110200 Vertical Flue Terminal 80/125

Available on request from: THE WHITE BOILER COMPANY Chartists way, Morley, Leeds, West Yorkshire ENGLAND LS27 9ET - U.K. Tel. 0113 252 7007

TEG060050 Flashing sleeve/slate

36

5.19 ASSEMBLE BOILER

Fit the gas service cock to the boiler via the union nut and connect gas pipe. Do not over tighten

3lts

5.20 Fitting valve pack Remove plastic caps from boiler connection and fit valves as per fig. 29 using washers provided.

It is recommended fitting the valve pack before installing the boiler on the wall.

5.21 GAS CONNECTION (Fig. 29)

A minimum working gas pressure of 20 mbar (8

in w.g.) must be available at the boiler inlet at full flow rate (37 mbar for propane, 29 mbar for butane).

Important consult (sect 4.6).

5.22 CENTRAL HEATING CONNECTION

(Fig. 29)

Fit the gas service cock to the boiler via the union nut and connect gas pipe. Do not over tighten and use another spanner as a counter force to avoid straining internal connections.

5.23 DOMESTIC HOT WATER CONNECTION (Fig. 29)

The domestic hot water circuit does not need

a safety valve but it is essential to ensure that the pressure of the cold water supply does not exceed 10 bar. If in doubt it is advisable to install a pressure reducing valve. The minimum pressure needed to operate the domestic hot water system is 0.5 bar with a flow of approx foreign matter from the supply pipe before

and after connecting to the appliance.

- Connect the 15 mm. cold water pipe to the appliance inlet.

- Connect the 15 mm. hot water pipe to the appliance outlet.

3lts per min. Flush out all

Before any central heating connections are made to the boiler all system valves should be opened and the system thoroughly flushed out with cold water.

- Connect the central heating return pipe to the isolating cock.

- Connect the central heating flow pipe to the isolating cock marked CHF.

- Pipe dimensions and positions are marked on template supplied (fig. 30).

Fig.29

5.24 POSITION OF WATER/GAS CONNECTIONS

Fig. 30

37

5.25 SAFETY VALVE DISCHARGE The safety valve is located to the rear

(15 mm copper) to permit a discharge pipe to be connected. When connecting ensure the

discharge pipe does not restrict access. The discharge should terminate facing downward exterior to the building in a position where discharging (possibly boiling water & steam) will not create danger or nuisance, an easily visible position, and not to cause damage to electrical components or wiring. The discharge must not be over an entrance or a window or any other type of access.

5.26 CONDENSATE DRAIN CONNECTION The condensate drain connection is a flexible

3/4” pipe and is therefore adjustable Fig. 29.

Notes: ALL EXTERNAL PIPE RUNS MUST BE IN ACCORDANCE WITH BS 6798

1 - INTERNAL TO SINK WASTE UPSTREAM OF SINK WASTE TRAP

The drain pipe should have a fall of a least

2.5° away from the boiler. Condensate should, if possible be discharged into the household internal drainage system.

If this is not practicable, discharge can be

allowed into the external household drains or a purpose designed soak away.

It is recommended that any external condensate

drain pipe is insulated and also must be of 40 mm (1” 1/2) diameter, through the outside wall to prevent freezing in adverse weather conditions.

It is not necessary to provide air breaks or extra

traps in discharge pipe as there is already a 125mm high trap inside the boiler.

Fitting an extra trap may cause the boiler siphon

to work incorrectly.

Refer to BS5546 or BS6798 for advice on

disposal of boiler condensate.

2 - INTERNAL CONNECTION TO SOIL VENT STACK Make connection to SVP using a solvent welded saddle.

Fig. 31

Fig. 32

38

3 - TERMINATION TO SOAK AWAY 4 - TERMINATION TO DRAIN / GULLY

authorised by th

as in section

6.9 and table 10, and adjust to correct data settings information.

8.2. You can slide towards the top the instrument panel box and push the retaining latches and remove the instrument panel (sect. 8.24).

- Heat resistant flexible cable is fitted between the isolator and the terminal block which is a 3 core cable

Fig. 33

5.27 CONVERTING THE APPLIANCE TO DIFFERENT GAS TYPES

Boilers are factory set to work for use

with Natural gas or LPG gas. This is

clearly marked on the packaging and

boiler data badge.

To convert a boiler from one gas to another this operation must be carried out by a qualified competent person, with all necessary equipment

authorised by the manufacturer.

It will also be necessary to obtain a data badge conversion kit directly from The White Boiler Company.

1 - Remove the case. 2 - Check gas mains pressure at the gas valve test nipple upstream (fig.35) with boiler operating (sect.6.8). 3 - Adjust fan speed as sect.3 (technical data). 4 - Measure the level of CO2

6.9 and table 10, and adjust to correct data settings information. 5 - Affix new data badge. 6 - Replace in reverse order.

5.28 ELECTRICAL CONNECTIONS IMPORTANT:

Electricity supply must be as specified in

clause (sect. 4.22).

- When controls external to the appliance are required, design of the external electrical circuits should be undertaken by a

competent person. In accordance with the

IEE wiring regulations.

as in section

Fig. 34

It is essential that all external controls are VOLT FREE.

Factory fitted internal wiring must not be disturbed when wiring external controls.

- To gain access to the electrical box remove the front panel of the case as described in clauses sect. You can slide towards the top the instrument panel box and push the retaining latches and remove the instrument panel (sect. 8.24).

- Heat resistant flexible cable is fitted between the isolator and the terminal block which is a 3 core cable of 0.75 mm2 (24x0,2 mm) to BS 6500.

Make sure all wires to the appliance are routed away from sharp edges and hot surfaces.

The cable must be fastened with its cord anchorage and connected so that should the cable slip from the anchorage the current carrying conductors become taut before the earthing conductor. Securely tighten all terminal screws and arrange the cable with slack between the cord anchorage and the terminal block.

WARNING: If the supply cord is damaged, it must be replaced by a service engineer (supply cord available from The White Boiler Company).

5.29 OUTDOOR SENSOR For use, consult Outdoor Sensor

instructions.

8.2.

39

6 COMMISSIONING

Continue filling the system until 1.5 bar

register on digital display.

Press the P button once again to return to the main screen.

1.5

E.g. time clock and thermostat) make sure that they are calling for heat.

- Select winter function, the winter icon in digital display will be flashing (item 3 fig.

2).

- To select the minimum heating temperature press the radiator button.

IMPORTANT:

Before lighting the boiler select the minimum

central heating temperature. This must be left at minimum for approx 5 mins to purge air safely from the boiler.

Each boiler has been through a rigorous operational testing procedure at our factory and should not require any further

adjustment, if you are not the installer but just commissioning this boiler check that the boiler has been installed in accordance with these instructions, and the integrity of the flue system and the flue seals, as described in the flue installation section.

6.1 GAS SUPPLY INSTALLATION Inspect the entire installation including the

gas meter, test for soundness and purge, all

as described in BS 6891. In Ireland refer to IS 813:2002.

6.2 ELECTRICAL INSTALLATION

Then turn off the filling points stopcock.

- Inspect the system for water soundness and remedy any leaks discovered.

6.4 SETTING THE HEATING SYSTEM DESIGN PRESSURE

The design pressure must be a min. 1 bar

and max. 1.5 bar. These figures are read on the digital display by pressing the P button.

The actual reading should ideally be 1 bar +

the height in metres to the highest point of the system above the base of the appliance (up to max of

N.B.: The safety valve is set to lift at 3 bar (30 mt/42.5 psi). To lower the system pressure to the

required value remove at the drain point (fig. 36) or drain on the heating circuit.

1.5 bar).

Preliminary electrical systems checks to

ensure electrical safety shall be carried out by

a competent person. ALWAYS carry out the preliminary electrical system checks: i.e. earth continuity, polarity, resistance to earth and short circuit, using a suitable test meter.

6.3 INITIAL FILLING OF THE SYSTEM

Open central heating flow and return valves

Unscrew the cap on automatic air release valve

positioned on the top of the pump housing one

full turn (leave open permanently).

- Close all air release taps on the central heating system. Press the P button to display the current pressure (code E8 will display if the pressure is nil/too low).

- Gradually open stopcock at the filling point connection to the central heating system until water is heard to flow.

- Starting with the lowest radiator open each air release tap in turn. Close it only when clear water, free of bubbles, flows out. In the same way release air from any high points in the pipework.

- register on digital display. button once again to return to the main screen.

GAS VALVE

Continue filling the system until 1.5 bar

Press the P

6.5 FILLING THE HOT WATER SYSTEM Close all hot water draw-off taps.

Open the cold water inlet cock. Slowly open each draw-of f tap until clear water

is discharged.

6.6 LIGHTING THE BOILER

Before lighting the boiler make sure that

the heating circuit flow and return valves are open and also that the cold water input cock is open.

- If external controls are installed ( clock and thermostat) make sure that they are calling for heat.

- Select winter function, the winter icon in

digital display will be flashing (item 3 fig.

2).

- To select the minimum heating temperature

press the radiator button.

IMPORTANT:

Before lighting the boiler select the minimum

central heating temperature. This must be left at minimum for approx 5 mins to purge air safely from the boiler.

Fig. 36

E.g. time

40

Fig. 35

-

To select the minimum heating temperature press the radiator button.

- Press arrow up and arrow down buttons to adjust.

- The digital display shows the current set temperature in central heating.

- After a few seconds the digital display shows the central heating temperature in demand (C.H. icon flashing, item 3 fig. 2).

- The fan starts and after a few seconds or so the digital led display will show that the ignition has commenced.

- NOTES: Put the digital clock in demand

position.

- The ignition control will automatically make

three attempts to start, if it doesn’t start this

may be due to air in the gas supply line. If the burner fails to light, the digital led display and fan will stop, and the display will show the lockout code (E1 depicts flame failure).

- If necessary push the boiler Reset button

(item 2 fig.1) and the boiler will restart automatically.

- After the boiler has lit, allow to warm at

minimum temperature setting to purge any air from the system.

- Once the system has been purged of air, set the heating temperature to the desired setting.

6.8 CHECK THE GAS PRESSURE

Check the gas mains pressure at the gas valve inlet pressure test point (fig.35) with the boiler operating at full rate. Check with the Local Gas supplier if the pressure differs significantly from 20 mbar G20 (natural gas), 37 mbar G31 (propane) and 29 mbar G30 (butane). With leak detection fluid test for gas tightness

of all gas components and joints.

IMPORTANT: The Gas Valve Throttle adjuster is required to be sealed with tamper proof paint after adjustment (fig. 35).

6.9

COMBUSTION CHECK

Check all gas carrying components along with,

the combustion of the appliance which should

be checked as follows. Remove the front panel of the appliance. Ensure the boiler and external controls are

calling for heat. Turn on the electrical supply.

open the hot water tap at maximum flow rate.

Wait at least five minutes or until the unit has

reached its operating temperature. Unscrew the test sample screw on the boiler

elbow bend (item 60 fig. 10). Measure the level

of CO

2

. Check the reading against the

corresponding value in table 10 and with

reference to page 63.

carrying out a combustion

measurement should have been assessed

It is essential that this test is repeated

with the casing on as this will check the integrity of the flue.

6.8 CHECK THE GAS PRESSURE

Check the gas mains pressure at the gas valve inlet pressure test point (fig.35) with the boiler operating at full rate. Check with the Local Gas supplier if the pressure differs significantly from 20 mbar G20 (natural gas), 37 mbar G31 (propane) and 29 mbar G30 (butane). With leak detection fluid test for gas tightness

The Gas Valve Throttle adjuster is required to be sealed with tamper proof paint after adjustment (fig. 35).

To select the minimum heating temperature press the radiator button.

- Press arrow up and arrow down buttons to adjust.

- The digital display shows the current set temperature in central heating.

- After a few seconds the digital display shows the central heating temperature in demand (C.H. icon flashing, item 3 fig. 2).

- The fan starts and after a few seconds or so the digital led display will show that the ignition has commenced.

- NOTES: Put the digital clock in demand

position.

- The ignition control will automatically make

three attempts to start, if it doesn’t start this

may be due to air in the gas supply line. If the burner fails to light, the digital led display and fan will stop, and the display will show the lockout code (E1 depicts flame failure).

- If necessary push the boiler Reset button

(item 2 fig.1) and the boiler will restart automatically.

- After the boiler has lit, allow to warm at

minimum temperature setting to purge any air from the system.

- Once the system has been purged of air, set the heating temperature to the desired setting.

of all gas components and joints.

IMPORTANT:

It is essential that this test is repeated

with the casing on as this will check the integrity of the flue.

If adjustment proves necessary then

proceed as follows.

IMPORTANT: Any adjustment to the gas

valve should only be carried out by a qualified person. Referring to the table 10, adjust the maximum level of CO

with the Throttle

2

using a 4 mm hex on the gas valve (fig.35). Anti-clockwise to decrease CO Clockwise to increase CO

.

2

After any new regulation wait to stabilise for about one minute. Replace the front cover.

TABLE 10

CO2%

NATGAS 9.0(+0.5/‐0.5) LPG 10.5(+0.5/‐0.5)

IMPORTANT: Do not insert the analyser

probe into the sample point immediately or leave in long periods. This will prevent saturation of the analyser.

During the calibration function the

combustion ratio may increase for a short time while the boiler performance is optimised.

The person measurement should have been assessed as competent in the use of a flue gas

carrying out a combustion

analyser.

The flue gas analyser used should be one

meeting the requirements of BS7927 or BSEN50379-3 and be calibrated in accordance with the analyser manufacturer’s requirements.

ELECTRODES POSITION

6.9

Remove the front panel of the appliance. Ensure the boiler and external controls are

Unscrew the test sample screw on the boiler

corresponding value in table 10 and with

COMBUSTION CHECK

Check all gas carrying components along with,

the combustion of the appliance which should be checked as follows.

calling for heat. Turn on the electrical supply.

open the hot water tap at maximum flow rate.

Wait at least five minutes or until the unit has reached its operating temperature.

elbow bend (item 60 fig. 10). Measure the level of CO

. Check the reading against the

2

reference to page 63.

Fig. 37

41

Once the process of commissioning the boiler is complete, the

commissioning engineer MUST complete the relevant section in the Benchmark log book.

ATTENTION

sec 1.5 key 5 to set heating

temperatures).

by a competent person. This will result in the boiler, at any time, periodically firing to keep the water within the boiler up to temperature to reduce the time delay of hot water delivered to any hot draw off point.

- Press P button (item 8 fig. 1) for 3 seconds to enter in menu.

- Use arrow up and arrow down buttons (item 5 and 6 fig. 1), to select BOIL.

- Press enter and reset buttons together

(item 1 and 2 fig. 1) and enter button again.

- Use arrow up and arrow down buttons (item 3 and 4 fig. 1) to select the following option:

- PM3 Keep hot (“0” disabled, “1” enable). Adjust if necessary.

6.14 C.H. HIGH/LOW TEMPERATURE

The boiler comes set, in Central heating, at the 80°C flow temperature. It is possible to adjust the max set-point to max 50°.

- Press P button (item 8 fig. 1) for 3

seconds to enter in menu.

- Use arrow up and arrow down buttons (item 3 and 4 fig. 1), to select BOIL.

- Press enter and reset buttons (item 1 and

8 fig. 1) together and enter button again.

- Use arrow up and arrow down buttons (item 3 and 4 fig. 1) to select the following option:

- PM4 (“1” high temperature, “2” low temperature).

IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE BENCHMARK

COMMISSIONING CHECKLIST IS FULLY COMPLETED AND LEFT WITH THE APPLIANCE

Once the process of commissioning the boiler is complete, the

commissioning engineer MUST complete the relevant section in the Benchmark log book.

6.10 CHECKING THE FLUE SYSTEM The flue system should be visually checked for

soundness. Check all connections and fixings are secure and tight.

6.11 CHECKING THE HEATING THERMOSTAT Allow the system to warm up and then select

the C.H thermostat to ensure the main burner modulates from “high” to “low” and “low” to “off” and vice versa (scale range covers approx

35°C - 80°C,

temperatures).

6.12 TESTING AND REGULATING THE DOMESTIC HOT WATER SYSTEM FLOW AND CHECK THE OPERATIONAL (WORKING) INLET PRESSURE

Set up the boiler to operate at maximum rate

by opening the hot tap to maximum flow. With the boiler operating at the maximum rate check the operational dynamic (working) gas pressure test complies with the requirements. Ensure that this inlet pressure can be obtained with all other gas appliances in the property working.

Put the appliance in summer position (item1

fig. 1).

- Open a domestic hot water tap (preferably

the bath tap). Ensure the cold water inlet stopcock is open and the D.H.W. is set at maximum, press the arrow up (item 3 fig.

1) the digital display shows the set

temperature, if necessary adjust with arrow up and arrow down buttons.

- After a few seconds the digital display

shows water temperature in demand (D.H.W. icon flashing, item 12 fig. 2).

- If the boiler does not light check that the water flow rate is above the min. required to operate the differential pressure 2.8 Lts./ min. (0.61 gals/min).

- The temperature of the water will depend on the rate at which it flows. If, due to high water pressure, the flow rate is too high (and the temperature too low for practical use) the flow rate may be adjusted.

It is better to set for the lowest acceptable

temperature preferably at the bath tap since the user can gain higher temperatures at other restricted flow taps.

sec 1.5 key 5 to set heating

42

- If the cold supply is subject to large fluctuations or is above the permitted max. water pressure, a suitable pressure/flow regulator should be fitted on the cold water supply to the appliance.

- Slowly close the draw off tap to reduce the flow rate to the min (approx. 2.8 litre/min).

- Select a different temperature for D.H.W. to ensure it operates at its various setting.

- Close the draw-off tap still further. The burner should stop when the rate falls below about 2.8 litres/min (0.61 gals/min).

6.13 KEEP HOT

The boiler comes with an optional keep hot facility. This can be switched on person. This will result in the boiler, at any time, periodically firing to keep the water within the boiler up to temperature to reduce the time delay of hot water delivered to any hot draw off point.

- Press P button (item 8 fig. 1) for 3 seconds to enter in menu.

- Use arrow up and arrow down buttons (item 5 and 6 fig. 1), to select BOIL.

(item 1 and 2 fig. 1) and enter button again.

- Use arrow up and arrow down buttons (item 3 and 4 fig. 1) to select the following option:

- PM3 Keep hot (“0” disabled, “1” enable). Adjust if necessary.

6.14 C.H. HIGH/LOW TEMPERATURE

at the 80°C flow temperature. It is possible to adjust the max set-point to max 50°.

seconds to enter in menu.

- Use arrow up and arrow down buttons (item 3 and 4 fig. 1), to select BOIL.

8 fig. 1) together and enter button again.

- Use arrow up and arrow down buttons (item 3 and 4 fig. 1) to select the following option:

- PM4 (“1” high temperature, “2” low temperature).

- Press enter and reset buttons together

The boiler comes set, in Central heating,

- Press P button (item 8 fig. 1) for 3

- Press enter and reset buttons (item 1 and

by a competent

user how to isolate the appliance from the gas, water and electricity supplies an

6.15 RANGE RATING CENTRAL HEATING

been adjusted by the manufacturer during production. If the adjustments need to be made again, observe the following procedures.

The adjustment to fan speed must be strictly in the sequence indicated, by qualified personnel only.

To check max fan speed, see tables 11/A and 11/B:

- Press P button (item 8 fig. 1) for 3

seconds to enter in menu.

- Use arrow up and arrow down buttons (item 3 and 4 fig. 1), to select BOIL.

- Press enter and reset buttons (item 2 and 3 fig. 1) together and enter button again.

- Use arrow up and arrow down buttons (item 3 and 4 fig. 1) to select the followings options:

- PM1 CH max fan speed.

the arrow up and the arrow down buttons, (item 3 and 4 ﬁ g. 1) for 5 seconds. Press the arrow up and the arrow down buttons to set the maximum or minimum fan speed. The function is enabled for maximum 15 minutes and it has priority on D.H.W. mode. Press reset to esc test mode.

6.17 INSTRUCTING THE USER

After completion of the installation and commissioning of the system, the installer should hand over to the Householder by taking the following actions:

- To the Householder explain His/her

responsibilities under the “Gas Safety Regulations 2000”.

- Explain and demonstrate the lighting and shutting down procedures.

OR/AND DOMESTIC HOT WATER

The boiler comes set, in Central heating, at the MID RANGE of its output.

The boiler has already

manufacturer during production. If the adjustments need to be made again, observe the following procedures.

The adjustment to fan speed must be strictly in the sequence indicated, by qualified personnel only.

To check max fan speed, see tables 11/A and 11/B:

seconds to enter in menu.

- Use arrow up and arrow down buttons (item 3 and 4 fig. 1), to select BOIL.

and 3 fig. 1) together and enter button again.

- Use arrow up and arrow down buttons (item 3 and 4 fig. 1) to select the followings options:

- PM1 CH max fan speed.

- Press P button (item 8 fig. 1) for 3

- Press enter and reset buttons (item 2

been adjusted by the

- PM2 DHW max fan speed.

- Press enter (item 1 fig. 1) to select CH or DHW fan speed. Adjust if necessary.

TABLE 11/A

Range rating regulation of Central Heating

C.H. regulations Heat input (kW) Fan speed (rpm)

WH 80 WH 90 WH 80 WH 90

Maximum setting 20 24,5 4200 4200

Minimum setting 3,7 4,1 1300 1300

TABLE 11/B

Range rating regulation of Domestic Hot Water

D.H.W. regulations Heat input (kW) Fan speed (rpm)

WH 80 WH 90 WH 80 WH 90

Maximum setting 25,4 30,1 4800 4800

Minimum setting 3,7 4,1 1300 1300

RATIO BETWEEN FAN SPEED AND HEAT INPUT

6.16 TEST MODE

It is possible to activate the test mode function by pressing arrow down buttons, (item 3 and 4 ﬁ g. 1) for 5 seconds. Press the arrow up and the arrow down buttons to set the maximum or minimum fan speed. The function is enabled for maximum 15 minutes and it has priority on D.H.W. mode. Press reset to esc test mode.

6.17 INSTRUCTING THE USER

After completion of the installation and commissioning of the system, the installer should hand over to the Householder by taking the following actions:

- To the Householder explain His/her

responsibilities under the “Gas Safety Regulations 2000”.

- Explain and demonstrate the lighting and shutting down procedures.

the arrow up and the

- Show the user the location of the filling valve and how to top-up the system pressure correctly.

- Explain the operation of the boiler including the use and adjustment of ALL system controls which should be fully explained to the Householder. This will ensure the optimum fuel economy for the household requirements of both heating and hot water consumption.

Advise the User of the precautions

Fig. 38

necessary to prevent damage to the system,

and to the building, in the event of the system remaining inoperative during frost conditions.

- Explain the function and t he use of the boiler, the summer/winter button, the

ON/OFF switch and the reset of t he digital

display.

- Explain and demonstrate the function of the temperature controls, radiator valves etc for the economic use of the system.

- If an external time clock is fitted, then draw attention to the digital time.

- Stress the importance of regular servicing by a qualified Heating Engineer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR.

- Fill in the Benchmark log book and leave completed with the customer.

- Explain to the appliance from the gas, water and electricity supplies and the locations of

user how to isolate the

all drain points.

43

7 SERVICING INSTRUCTIONS

(Refer to

table 10 and page 63).

- Check all joints and connections in the appliance and remake any that show signs of leakage.

NOTE: Service consumables are not covered by the warranty. To view warranty exclusions please visit www.ravenheat.co.uk or contact us on 01132 527007.

COMPETENCE TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE.

Please note: BS6798:2009 Specification for installation and maintenance of gas-fired boilers of rated input not exceeding 70 kW net advises that:

- The person carrying out a combustion measurement should have been a

satisfactory completion of th

7.1 BOILER FROST PROTECTION

The White Boiler Company is a member of the Benchmark initiative and fully supports the aims of the programme. Benchmark was instructed to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.

using a combustion analyser conforming to BS7927.

Combustion testing must be carried out by competent person

During routine servicing, and after any maintenance or change of part of the combustion circuit, the following must be checked:

- The integrity of the flue system and the flue seals.

- The integrity of the boiler combustion circuit and the relevant seals.

- The operational dynamic (working) gas inlet pressure at maximum rate.

- The gas rate.

- The combustion performance table 10 and page 63).

- Check all joints and connections in the appliance and remake any that show signs of leakage.

NOTE: Service consumables are not covered by the warranty. To view warranty exclusions please visit www.ravenheat.co.uk or contact us on 01132 527007.

COMPETENCE TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE.

Please note: BS6798:2009 Specification for installation and maintenance of gas-fired boilers of rated input not exceeding 70 kW net advises that:

- The person carrying out a combustion measurement should have been assessed

(Refer to

as competent in the use of a flue gas analyser and the interpretation of the results.

- The flue gas analyser used should be one meeting the requirements of BS7927 or BS-EN 50379-3 and be calibrated in accordance with the analyser manufacturers requirements.

- Competence can be demonstrated by

satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967, Parts 1 to 4.

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 falls below 10°C and will operate the burner when the temperature falls below 5°C. The burner will switch off when the temperature reaches 27°C.When the frost protection device operates “AF” is displayed on the digital display.

IMPORTANT NOTE: The system should be protected by incorporating a

system frost thermostat.

To ensure continued efficient operation of the appliance it is necessary to carry out servicing and cleaning at regular intervals. The frequency of servicing and cleaning

will depend upon the particular installation conditions and usage but in general, once a year is advisable.

WARNING: Before the start of any servicing or replacement of components always isolate the electricity supply to the appliance and always turn off the appliance gas supply at the gas service cock.

The Data badge is positioned low on the inside left panel.

- The following notes apply to the appliance and its controls but it should be remembered that attention must also be paid to the heating and hot water circuits with special attention to radiator valves, thermostats, clocks, leaking hot water taps etc.

- Where it is necessary to replace a gasket that relies on adhesive for securing - this adhesive will be supplied with the gasket as a spare item.

- In all cases prior to servicing, remove the front panel of the case. Operate the appliance by turning the hot water services on to a high water flow. Measurement of the products of combustion can be achieved by connection of a probe to the combustion analyser test point.

44

- IMPORTANT:

Examine and remove loose debris from the combustion chamber using a soft brush and vacuum cleaner. Carefully flush,

by spraying water at any remaining debris

through the condensate trap. (Ensure the water is kept away from electrical components).

Inspect the siphonic condensate trap for a blockage. Remove the cap at the base

of the condensate trap. Remove an

After replacing any parts always test for gas soundness and if necessary carry out functional test of the controls.

For replacement of parts, the front, and bottom panels of the boiler will need to be removed (it is not necessary to remove the side panels as all parts are accessible from the front or beneath the boiler).

8.2 TO REMOVE THE BOILER PANELS

To remove the front panel unscrew the two

lower screws that secure the front panel to

the boiler and lift off To remove the bottom panel unscrew the four screws and lift off.

After completing any servicing or replacement of gas carrying components it

is essential that a test for gas soundness is always carried out along with functional checks in operation.

7.2 TO INSPECT AND CLEAN THE APPLIANCE

8 REPLACEMENT OF PARTS

8.1 GENERAL

Replacement of parts must be carried out by a competent person.

Before replacing any parts the boiler should

be isolated from the mains electric supply and the gas should be turned off at the service cock on the boiler.

Before carrying out the cleaning operation, cover the electrical control panel with a piece of waterproof material to protect it from debris. Inspect the heat exchanger for any

blockage. Deposits of any material should be brushed away using a soft brush.

NOTE: Do not use brushes with metallic

bristles.

Examine internal pipe-work connections and automatic air vent for any water leaks

and rectify if necessary.

the combustion chamber using a soft brush and vacuum cleaner. Carefully flush,

(Ensure the water is kept away from electrical components).

a blockage. Remove the cap at the base

Any deposits should be flushed out. Reassemble and refit the condensing

When refitting the cap ensure that a

Examine and remove loose debris from

by spraying water at any remaining debris through the condensate trap.

Inspect the siphonic condensate trap for of the condensate trap. Remove any

debris found. Remove the float to clean it.

trap. watertight seal is achieved, but do not use

excessive force.

Examine the spark and sensing electrodes

for any mechanical damage. Clean away any debris and check the spark and sensing gap.

Examine flue duct and flue manifold and

ensure that there is no obstruction. Examine the gasket at the entry into the flue manifold.

8.2 TO REMOVE THE BOILER PANELS

To remove the front panel unscrew the two

To remove the bottom panel unscrew the four screws and lift off.

After replacing any parts always test for gas soundness and if necessary carry out functional test of the controls.

For replacement of parts, the front, and bottom panels of the boiler will need to be removed (it is not necessary to remove the side panels as all parts are accessible from the front or beneath the boiler).

lower screws that secure the front panel to the boiler and lift off..

It is essential that a good seal is made at

the outlet to the flue manifold, renew this gasket if there is any sign of damage or deterioration.

Fig. 39

45

the retaining clip. Detach the connectors from the fan. Unscrew the four screw that fix the fan and

remove only the right screws. Pull the fan to the right and pull forward. Replace in reverse order (always fitting a

new gasket).

Remove front panel (fig. 39).

Unscrew the four screw to the bottom

panel.

Unscrew the two screws to the side panel

rotate 48 mm and unhook.

8.3 TO REMOVE LEFT AND RIGHT PANELS (Fig. 40)

Unscrew the four screw to the bottom

8.4 TO REMOVE/REPLACE SPARK

IGNITER BOX (Fig. 41) Remove front panel (fig. 39).

Detach all the connectors from the igniter Remove the 2 screws that secure the spark Replace in reverse order.

Remove front panel (fig. 39).

panel.

Unscrew the two screws to the side panel

rotate 48 mm and unhook.

control box. igniter to the bracket.

Fig.40

Fig.41

8.5 TO REMOVE/REPLACE FAN (Fig. 42)

Remove front panel (fig. 39).

Unscrew the gas pipe nut and remove the retaining clip. Detach the connectors from the fan. Unscrew the four screw that fix the fan and

remove only the right screws. Pull the fan to the right and pull forward. Replace in reverse order (always fitting a

new gasket).

Fig.42

46

8.6 TO REMOVE/ REPLACE THE

Replace with a new

the fan.

U

Follow the instructions to remove the burner (sect. 8.7). Pull down to remove the condens

O-ring sea

ELECTRODES (Fig.37)

8.7 TO REMOVE/REPLACE THE BURNER (FIG.43)

Remove front panel (fig. 39).

Remove the ignition and/or sensing lead plug. Unscrew the two securing screws and put

them into a suitable container so that they

don’t get lost. Withdraw the Spark electrode and/or sensing electrode carefully from the burner

cover being careful not to damage the

seal.

Replace with a new electrode in reverse

order. Ensure the gap is correct and there

is a good seal when replaced (always

fitting a new gasket).

Remove front panel (fig. 39). Unscrew the gas pipe nut and remove the retaining clip. Detach the connectors from

the fan.

Unscrew the screws to the burner cover

and remove the cover with the fan. To remove the burner, unscrew the screws in the lower cover side. Replace in reverse order (always fitting a

new gasket).

8.8 TO REMOVE/REPLACE THE MAIN HEAT EXCHANGER

Remove front and bottom panels (fig. 39-40). Drain the boiler CH circuit and drain the DHW circuit.

remove the burner (sect. 8.7). Pull down to remove the condense pipe on the bottom of the heat exchanger. Disconnect the flow and return pipes at the heat exchanger.

Loosen the four heat exchanger securing screws and clamps then carefully ease the heat exchanger out.

Follow the instructions to

Fig.43

CAUTION : There will be water in the heat exchanger.

Replace in reverse order, always use new

O-ring seals.

47

8.9 TO REMOVE/REPLACE EXPANSION

Unscrew the nut and the four screws on

the bottom of the gas valve.

Replace in reverse order.

Unscrew the two al

VESSEL (Fig.44)

Remove front and bottom panels (fig. 39-40). Drain the CH circuit, unscrew the fixing bracket and the nut connecting the expansion vessel. Lift up the vessel and remove. Replace in reverse order. Use a new gasket, taking care to ensure they are replaced correctly.

8.10 TO REMOVE/REPLACE GAS VALVE (Fig. 45)

Remove front and bottom panels (fig. 39-40). Unscrew the nut and the four screws on

the bottom of the gas valve.

Replace in reverse order. IMPORTANT:

when the gas valve is re-fitted, check

combustion CO2 and adjust if necessary (see section 6.9).

8.11 TO REMOVE/REPLACE PLATE HEAT

EXCHANGER (Fig. 46)

Remove front and bottom panels

(fig. 39-40). Remove the panel control box (sect.

8.23). Close off the on/off valves for CH circuit and DHW circuit and drain the boiler and drain hot water from the lowest hot water tap.

connect the DHW heat exchanger and pull it out from the boiler (fig. 46). If necessary the pipes from the flow manifold may have to be removed for easier access. Lift up the plate heat exchanger. Replace in reverse order. NOTE: Always use new O-rings.

Unscrew the two allen screws that

Fig.44

Fig.45

8.12 TO REMOVE/REPLACE THE WATER PRESSURE TRANSDUCER (Fig. 45)

Remove front and bottom panels

(fig. 39-40). Close the on/off valves for the heating circuit and drain the water at drain point (fig.36). Detach the wire connector, remove the securing clip. Replace in reverse order.

48

Fig.46

8.13 TO REMOVE/REPLACE DIVERTER VALVE

Detach the electrical plug and remove the

retaining clip.

Replace in reverse order.

8.14 TO REMOVE/REPLACE C.H. DIVERTER VALVE (Fig. 47)

Remove the panel control box (sect. 8.23).

Close the on/off valves for the heating circuit and drain the water at drain point (fig.36). Remove diverter valve motor switch, to allow access and unscrew the

C.H.diverter valve (fig.47). Replace in reverse order. NOTE: Always use new O-ring.

Close the on/off valves for the heating

circuit and drain the water at drain point (fig.36).

Detach

the supply wire connector from the

pump.

Unscrew the nut that fastens the pump to

the CH pipe and remove the pump and remove the securing clip at the pump

manifold. Replace in reverse order. NOTE:

Always use new O-ring.

Remove the panel control box (sect. 8.23). Close the on/off valves for C.H. circuit and drain the water from at drain point Fig.36. Remove the clip and pull the automatic air

vent from the pump. Replace in reverse order. NOTE: Always use new O-ring.

Remove the panel control box (sect. 8.23).

Close the on/off valves for the heating circuit and drain the water at drain point (fig.36).

Remove flow detector and unscrew DHW

diverter valve. Replace in reverse order. NOTE: Always use new O-ring

MOTOR (Fig. 47)

Remove front and bottom panels (fig. 39-40). Detach the electrical plug and remove the

8.14 TO REMOVE/REPLACE C.H. DIVERTER VALVE (Fig. 47)

Remove front and bottom panels (fig. 39-40). Remove the panel control box (sect. 8.23).

Replace in reverse order. NOTE: Always use new O-ring.

retaining clip.

Close the on/off valves for the heating circuit and drain the water at drain point (fig.36). Remove diverter valve motor switch, to allow access and unscrew the C.H.diverter valve (fig.47).

Replace in reverse order.

8.15 TO REMOVE/REPLACE D.H.W. DIVERTER VALVE MECHANISM ( Fig. 47)

Remove front and bottom panels (fig. 39-40). Remove the panel control box (sect. 8.23).

Close the on/off valves for the heating

circuit and drain the water at drain point

(fig.36). Remove flow detector and unscrew DHW

diverter valve. Replace in reverse order. NOTE: Always use new O-ring.

Fig.47

8.16 TO REMOVE/REPLACE PUMP (Fig.48) Remove front and bottom panels

(fig. 39-40). Close the on/off valves for the heating

circuit and drain the water at drain point (fig.36).

Detach

pump.

Unscrew the nut that fastens the pump to

the CH pipe and remove the pump and

Replace in reverse order. NOTE:

remove the securing clip at the pump manifold.

the supply wire connector from the

Always use new O-ring.

8.17 TO REMOVE/REPLACE AUTOMATIC AIR VENT (Fig. 48)

Remove front and bottom panels

(fig. 39-40).

Replace in reverse order. NOTE: Always use new O-ring.

Remove the panel control box (sect. 8.23). Close the on/off valves for C.H. circuit and drain the water from at drain point Fig.36. Remove the clip and pull the automatic air vent from the pump.

Fig.48

49

Close the on/off valves for C.H. circuit and

drain the water from at drain point fig.36.

Unscrew the safety relief valve screw and

pull up.

Replace in reverse order and using a new

gasket.

8.19 TO REMOVE/REPLACE D.H.W. SENSOR (Fig. 47)

Close the on/off valve for the DHW circuit

and drain the hot water from the lowest hot water tap.

Detach the wire connector and unscrew the

sensor.

Replace in reverse order.

8.20 TO REMOVE/REPLACE C.H. FLOW AND

RETURN SENSORS (Fig. 49)

Detach the wire connector and remove

the retaining cli

f

front panel (fig. 39), bottom and

left side panels (fig. 40). Remove the securing clip and pull out the plastic pipe that connects the condensing trap at the heat exchanger. Unscrew the nut that fastens the condensing trap to the depr

8.18 TO REMOVE/REPLACE SAFETY RELIEF VALVE (Fig. 47)

Remove front and bottom panels (fig. 39-40). Close the on/off valves for C.H. circuit and

drain the water from at drain point fig.36.

Unscrew the safety relief valve screw and

pull up.

Replace in reverse order and using a new

gasket.

8.19 TO REMOVE/REPLACE D.H.W. SENSOR

Remove front and bottom panels (fig. 39-40). Close the on/off valve for the DHW circuit

Detach the wire connector and unscrew the

8.20 TO REMOVE/REPLACE C.H. FLOW AND

(Fig. 47)

and drain the hot water from the lowest hot water tap.

sensor.

Replace in reverse order.

RETURN SENSORS (Fig. 49)

Fig.49

Remove front panel (fig. 39). Detach the wire connector and remove

the retaining clip sensor from the pipe. NOTE: When reconnecting ensure the correct wires go to the relevant sensor

(the polarity on each one is unimportant).

8.21 TO REMOVE/REPLACE FLUE SENSOR (Fig. 3 item 22)

Remove

Detach the wire connector and rotate the sensor.

Replace in reverse order.

front panel (fig. 39).

8.22 TO CLEAN AND REMOVE/REPLACE CONDENSING TRAP (Fig. 50)

Remove

left side panels (fig. 40). Remove the securing clip and pull out the plastic pipe that connects the condensing trap at the heat exchanger. Unscrew the nut that fastens the condensing trap to the depression chamber and remove it. If the side panel can not be removed then

remove the gas valve (see sec 8.10) and

continue with the above instructions. Replace in reverse order.

front panel (fig. 39), bottom and

50

Fig.50

8.23 TO REMOVE PANEL CONTROL BOX

front panel (fig. 39). Pull forward the control panel box with both hands until it is slightly out of the boiler. As doing so move the box

front panel (fig. 39). Push the four retaining latches and remove the front of the panel box (fig.

54).

8.25 TO REMOVE/REPLACE CONTROL BOARD (Fig.55).

Remove front panel (fig. 39).

Remove the instrument panel (sect.

8.24). Detach all connectors from control board, unscrew the four screws and lift up. Replace in reverse order (fig. 55).

8.26 TO REMOVE/REPLACE DIGITAL DISPLAY BOARD.

Remove the front panel (fig. 39). Remove the instrument panel (8.24). Detach the connectors and unscrew the four screws. Replace in reverse order.

8.27 EXTERNAL CONTROL CONNECTION (Fig. 54)

Remove front panel (fig. 39). Remove the external wire link on the panel control box. Replace with external wire controls.

(These must be volt free).

(Fig. 51,52,53). Remove

Pull forward the control panel box with both hands until it is slightly out of the boiler. As doing so move the box over to the left while still pulling it forward until the control box becomes free. Lift and fix the box on the depression chamber with the service retaining clips (fig. 53). This will allow free access to lower part of the boiler.

front panel (fig. 39).

Fig.52

Fig.51

8.24 TO REMOVE THE INSTRUMENT PANEL (Fig. 54).

Remove

Push the four retaining latches and remove the front of the panel box (fig.

54).

8.25 TO REMOVE/REPLACE CONTROL BOARD (Fig.55).

Remove the instrument panel (sect.

8.24). Detach all connectors from control board, unscrew the four screws and lift up. Replace in reverse order (fig. 55).

Remove front panel (fig. 39).

front panel (fig. 39).

Fig.53

8.27 EXTERNAL CONTROL CONNECTION (Fig. 54)

Remove the external wire link on the panel control box. Replace with external wire controls.

Remove front panel (fig. 39).

(These must be volt free).

Fig.54

8.26 TO REMOVE/REPLACE DIGITAL DISPLAY BOARD.

Remove the instrument panel (8.24). Detach the connectors and unscrew the four screws. Replace in reverse order.

Remove the front panel (fig. 39).

Fig.55

51

9 FAULT FINDING CENTRAL HEATING

Before trying to operate the boiler make sure that: all gas supply cocks are open and the gas supply has been

purged of air. The heating system pressure is at least 1 bar min to 1.5 bar max, select winter position on the digital display and set the central heating temperature to maximum. (sect. 1.5). Ensure external controls are calling for heat (room thermostat/ digital clock) and check the following appliance operations:

52

see section 9, and after selecting the summer position on the digital display and setting

the domestic hot water temperature to maximum (

9.1 FAULT FINDING DOMESTIC HOT WATER

Before continuing

the domestic hot water temperature to maximum (sect.1.5). Open the domestic hot tap and check the following appliance operations:

see section 9, and after selecting the summer position on the digital display and setting

53

10 ELECTRICAL SYSTEM DIAGRAM

54

Fig. 61

11 SPARE PARTS

Fig. 62

55

THE WHITE BOILER COMPANY WH 80/90 (T)

HIGH EFFICIENCY CONDENSING COMBINATION BOILER

SHORT LIST OF SPARE PARTS AND FLUE ACCESSORIES

Pos. Part. No. G.C.

Part. No.

1 CIR150100 Digital display 2 PAN150050 Instrument panel

3 CIR150050 Control board 4 SCA110051 Instrument panel box 5 FUS010150 Internal fuse 3.15 A 6 TRA15010 Water pressure transducer 7 FOR150250 Water pressure transducer clip

8 GRU150100 Return manifold 9 GRU150100 Turbine manifold 10 ORI110450 Plate heat exchanger O-ring 11 SCA150150 WH 80 plate heat exchanger

11.1 SCA150200 WH 90 plate heat exchanger 12 VAL150250 Drain valve

13 GRU150050 Flow manifold 14 VAL150100 Safety relief valve 15 5018025 1/2” gasket 16 TUB150480 Safety relief valve pipe 17 TUR150050 Turbine 18 RIV150050 Flow detector switch 19 TER150050 D.H.W. sensor 20 OTT150050 Diverter valve by-pass 21 FOR150050 Diverter valve motor clip 22 MOT150050 Diverter valve motor

Description

(GUA010200)

23 5018030 3/4”gasket 24 TUB150150 Gas valve inlet pipe 25 TUB150070 Flow pipe 26 SON110100 C.H. ﬂ ow and return sensors 27 ORI150100 Primary heat exchanger O-ring 28 FOR150050 Primary heat exchanger clip 29 TER080050 Overheat thermostat (TER060150) 30 VAL150200 Manual air vent 31 TUB110150 Flexible condensing pipe (TUB110300) 32 RAC110050 Condensing trap 33 FAS150050 Condensing trap pipe hose clamp 12-22 34 TUB150050 Condensing pipe 35 FAS150100 Condensing trap hose clamp 30-45 36 GUA010260 3/4” gas valve gasket 37 VAL150150 Gas valve 38 TUB150200 Gas valve outlet pipe 39 RAC150050 Air/gas mixer junction 40 ORI150050 Air/gas mixer junction O-ring

(GUA010250)

(SON110150)

56

Pos. Part. No. G.C.

Description

Part. No.

41 FOR150100 Air/gas mixer junction clip 42 MIX150050 WH 90 air/gas mixer

42.1 MIX150100 WH 80 air/gas mixer 43 ORI110050 Air/gas mixer - fan O-ring

44 VEN130100 Fan 45 GUA110051 Fan - burner gasket 46 CAN150100 Sensing electrode 47 CAN150050 Spark electrode

48 GUA150050 Sensing/spark electrode gasket 49 GUA150100 WH 90 burner gasket

49.1 GUA150120 WH 80 burner gasket 50 BRU150050 WH 80 burner

50.1 BRU150100 WH 90 burner 51 FLA110050 Flue ﬂ ange

(FLA110052)

52 GUA110350 Flue ﬂ ange gasket 53 GUA110250 Flue manifold washer

(GUA130050)

54 TER130050 Temperature ﬂ ue sensor 55 GEN150100 Spark igniter 56 COL150050 Flue exhaust manifold 57 SCA150050 WH 80 main heat exchanger

57.1 SCA150100 WH 90 main heat exchanger 58 VAS150050 Expansion vessel 59 GUA050050 3/8” gasket

(GUA060111)

60 TUB150120 Expansion vessel pipe 61 GUA010050 1/4” gasket

62 TUB150070 Flow pipe 63 GUA010310 1” gasket (GUA010311) 64 CIR150100 Pump 65 ORI150150 Pump O-ring 66 FOR150200 Pump clip / IMP150050 WH 80-90 (T) wiring harness

57

Plume Management Kit (see sect. 5.6)

Part. No. Description

TER110101 1 metre high plume kit CUR110050 45° ﬂ ue exhaust deﬂ ection bend CUR11010 90° ﬂ ue exhaust deﬂ ection bend

Accessories concentric flue 60/100 (see sect. 5.12 - Table 7)

Part. No. Description

PR5094110A Straight ﬂ ue header / sample point 60/100 PRFE Flue Extension 60/100 L1000 PR45FBI 45° bend 60/100 PR90FBI 90° elbow bend 60/100 PR5023016 Horizontal terminal 60/100 TER110200 Vertical ﬂ ue Terminal

Accessories concentric flue 80/125 (see sect. 5.18)

Part. No. Description

PR5094110A Straight ﬂ ue header / sample point 60/10 PRO110300 Flue Extension 80/125 L1000 RID110050 125/80 to 100/60 Flue reducer CUR110250 45° bend 80/125 CUR110300 90° elbow bend 80/125 TER010050 Horizontal Flue Terminal 80/125 TER110200 Vertical Flue Terminal 80/125 TEG060050 Flashing sleeve/slate

Accessories eccentric flue 80/80 (see sect. 5.13 - 5.14 - 5.15 - 5.16 - 5.17)

Part. No. Description

SDO110100 Twin ﬂ ue header F80/80 PRO110200 Straight pipe L1000 80 CUR110150 90° elbow bend 80 CUR110250 45° bend 80 GRI110050 Air inlet terminal 80 GRI110100 Exhaust terminal 80 TER060110 Vertical eccentric ﬂ ue terminal

58

THE WHITE BOILER COMPANY

A Ravenheat Group Company

Chartists Way, Morley, Leeds, LS27 9ET

Telephone: 0113 252 7007 Fax: 0113 238 0229 Website: www.ravenheat.co.uk E-mail: sales@ravenheat.co.uk

Ravenheat reserves the right to make changes and

improvements in our products which may affect the accuracy

of the information contained in this leaﬂ et.

COD 0017LIB15005/0 07/2014

12 BENCHMARK COMMISSIONING CHECKLIST DETAILS

Boiler Page Page

Make and model ………………………………………14/17 Burner operating pressure….....................................n/a

Appliance serial no. on data badge………..Left side panel Central heating ﬂ ow temp……... measure and record

Controls Central heating return temp…….measure and record

Temperature control to heating…………...................…12 For combination boilers only

Temperature control to hot water…………...............….12 Scale reducer………………………………..................25

Heating zone valves……………………………………..n/a Hot water mode

Auto by-pass………………………………………………22 Max. operating burner pressure….measure and record

Boiler interlock…………………………………….……....22 Max. operating water pressure…...measure and record

Cold water inlet temp…………….. measure and record

For all boilers Hot water temp……………………. measure and record

Flushing to BS7593………………………………...…….24 Water ﬂ ow rate at max. setting…...measure and record

Inhibitor…………………………………………………….25 For condensing boiler only

Central heating mode Condensate drain………………………………......38/39

Heat input………………………………….to be calculated For all boilers: complete, sign & hand over to the customer.

NOTE TO THE INSTALLER:

COMPLETE

THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE

INSTRUCTIONS WITH APPLIANCE

For assistance please call The White Boiler Company technical helpline: telephone: 0113 252 7007 fax: 0113 238 0229 e-mail: sales@ravenheat.co.uk

60

61

62

Benchmark Commissioning and Servicing Section

It is a requirement that the boiler is installed and commissioned to the manufacturers instructions and the data ¿elds on the commissioning checNlist completed in full.

7o instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation.

7o maintain the boiler guarantee it is essential that the boiler is serYiced annually by a *as 6afe registered engineer who has been trained on the boiler installed.

7he serYice details should be recorded on the %enchmarN6erYice InterYal 5ecord and left with the householder.

www.centralheating.co.uk

63

FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO

CHECK ON COMMISSIONING A CONDENSING BOILER

64

12.1 ANALYSER CHECK LIST

65

THE WHITE BOILER COMPANY

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

)ailure to install and commission according to the manufacturer¶s instructions and complete this %enchmarN Commissioning ChecNlist will inYalidate the warranty. 7his does not affect the customer ¶s statutory rights.

Customer name7elephone number

$ddress

%oiler maNe and model

%oiler serial number

Commissioned by (35I17 1$0()*as 6afe register number

Company name7elephone number

Company address

Commissioning date

To be completed by the customer on receipt of a Building Regulations Compliance Certi¿cate

%uilding 5egulations 1oti¿cation 1umber (if applicable)

CONTROLS (ticN the appropriate bo[es)

7ime and temperature control to heating

7ime and temperature control to hot water Cylinder thermostat and programmertimer Combination %oiler

Heating ]one YalYes Fitted 1ot required

Hot water ]one YalYes Fitted 1ot required

7hermostatic radiator YalYes Fitted 1

$utomatic bypass to system Fitted 1ot required

%oiler interlocN 3roYided

ALL SYSTEMS

7he system has been Àushed and cleaned in accordance with %6 and boiler manufacturer¶s instructions Yes

:hat system cleaner was used"

:hat inhibitor was used" 4uantity litres

Has a primary water system ¿lter been installed" Yes 1o

CENTRAL HEATING MODE measure and record

*as rate mñhr OR ftñhr

%urner operating pressure (if applicable) mbar OR *as inlet pressure mbar

Central heating Àow temperature C

Central heating return temperature C

COMBINATION BOILERS ONLY

Is the installation in a hard water area (aboYe ppm)" Yes 1o

If yes and if required by the manufacturer has a water scale reducer been ¿tted" Ye s 1o

:hat type of scale reducer has been ¿tted"

DOMESTIC HOT WATER MODE 0easure and 5ecord

*as rate mñhr OR ftñ

%urner operating pressure (at ma[imum rate) mbar OR *as inlet pressure at ma[imum rate mbar

Cold water inlet temperature C

Hot water has been checNed at all outlets Yes Temperature C

:ater Àow rate Imin

CONDENSING BOILERS ONLY

The condensate drain has been installed in accordance with the manufacturer¶s instructions andor %6%6 Ye s

ALL INSTALLATIONS

5ecord the following

The heating and hot water system complies with the appropriate %uilding Regulations Yes

The boiler and associated products haYe been installed and commissioned in accordance with the manufacturer¶s instructions Yes

The operation of the boiler and system controls haYe been demonstrated to and understood by the customer Yes

The manufacturer¶s literature including %enchmarN ChecNlist and 6erYice Record has been e[plained and left with the customer Yes

Commissioning (ngineer¶s 6ignature

Customer¶s 6

(To con¿rm satisfactory demonstration and receipt of manufacturer ¶s literature)

ignature

$t ma[. rate CO ppm AND COCO

$t min. rate (where possible) CO ppm AND COCO

5oom thermostat and programmertimer 3rogrammable room thermostat

/oadweather compensation Optimum start control

ot required

²

Ratio

hr

 $ll installations in (ngland and :ales must be noti¿ed to /ocal $uthority %uilding Control (/$%C) either directly or through a

Competent 3ersons 6cheme. $ %uilding 5egulations Compliance Cer ti¿cate will then be issued to the customer.

www.centralheating.co.uN

g

)

SERVICE RECORD

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider

%efore completing the appropriate 6erYice Record below please ensure you haYe carried out the serYice as described in the manufacturer¶s instructions. $lways use the manufacturer¶s speci¿ed spare part when replacing controls.

SERVICE 01

(ngineer name

Company name

Telephone 1o

*as safe register 1o

Record

Comments

6ignature

$t ma[. rate CO ppm AND CO

$tmin.rate

(:here 3ossible) CO ppm AND CO

SERVICE 03

(ngineer name

Company name

Telephone 1o

*as safe register 1o

Record

Comments

6ignature

$tma[.rate CO ppm AND CO

$tmin.rate

(:here 3ossible) CO ppm AND CO

SERVICE 05

(ngineer name

Company name

Telephone 1o

*as safe register 1o

Record

Comments

$tma[.rate CO ppm AND CO

$t min. rate

(:here 3ossible) CO ppm AND CO

'ate

SERVICE 02

(ngineer name

Company name

Telephone 1o

*as safe register 1o

%

²

%

²

Record

Comments

6ignature

$tma[.rate CO ppm AND CO

$t min. rate

(:here 3ossible) CO ppm AND CO

SERVICE 04

(ngineer name

Company name

Telephone 1o

*as safe register 1o

%

²

%

²

Record

Comments

6ignature

$tma[.rate CO ppm AND CO

$t min. rate

(:here 3ossible) CO ppm AND CO

SERVICE 06

(ngineer name

Company name

Telephone 1o

*as safe register 1o

%

²

%

²

Record

Comments

$tma[.rate CO ppm AND CO

$tmin.rate

(:here 3ossible) CO ppm AND CO

'ate

%

²

%

²

%

²

%

²

%

²

%

²

6ignature

SERVICE 07

(ngineer name

Company name

Telephone 1o

*as safe register 1o

Record

Comments

6ignature

$tma[.rate CO ppm AND CO

$t min. rate

(:here 3ossible) CO ppm AND CO

SERVICE 09

(ngineer name

Company name

Telephone 1o

*as safe register 1o

Record

Comments

6ignature

$tma[.rate CO ppm AND CO

$t min. rate

(:here 3ossible) CO ppm AND CO

'ate

6ignature

SERVICE 08

(ngineer name

Company name

Telephone 1o

*as safe register 1o

%

²

%

²

Record

Comments

6ignature

$tma[.rate CO ppm AND CO

$tmin.rate

(:here 3ossible) CO ppm AND CO

SERVICE 10

(ngineer name

Company name

Telephone 1o

*as safe register 1o

%

²

%

²

Record

Comments

6ignature

$tma[.rate CO ppm AND CO

$tmin.rate

(:here 3ossible) CO ppm AND CO

'ate

%

²

%

²

%

²

%

²

 $ll installations in (ngland and :ales must be noti¿ed to /ocal $uthority %uilding Control (/$%C) either directly or through a

Competent 3ersons 6cheme. $ %uilding Regulations Compliance Certi¿cate will then be issued to the customer.

and Hotwater Industry Council (HHIC

www.centralheating.co.uN

Ravenheat WH 80/90 (T) INSTRUCTIONS FOR USE

Specifications and Main Features

Frequently Asked Questions

User Manual