Ravenheat WH System 3-20/4-24 INSTRUCTIONS FOR USE INSTALLATION AND SERVICING

THE WHITE BOILER COMPANY

Instructions for Use

Installation and Servicing

To be left with the user

SYSTEM BOILER

HIGH EFFICIENCY

CONDENSING

WH System 3-20

Natural Gas (G20) II

LPG (G31) II

G.C. No.

2H3P

G. C. No.

2H3P

WH System 4-24

Natural Gas (G20) II

LPG (G31) 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, U.K. LS27 9ET
TEL.: [phone] - FAX: [phone]

Website: www.ravenheat.co.uk - E-mail: [e-mail]

2H3P

G.C. No.

G. C. No.

2H3P

1312

2

EFFICIENCY CONDENSING BOILER

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.

- Built in frost protection.

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

- Aesthetically pleasing panels and controls.

- On/Off ball valves for shutting off gas and central heating.

- Safety relief valve (for safety discharge).

effi ciency of thi

HAZARDOUS TO HEALTH

IMPORTANT

HIGH

FOR CENTRAL HEA TING AND DOMESTIC HOT WATER

This new highly effi cient turbo-modulating boiler is designed to meet 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.

-

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

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

- Unique

- Built in frost protection.

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

- Aesthetically pleasing panels and controls.

- On/Off ball valves for shutting off gas and central heating.

- Safety relief valve (for safety discharge).

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

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

MAJOR COMPONENTS

for high thermal fl ue transfer from gases to water.

IMPORT ANT

HAZARDOUS TO HEAL TH

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 23

1.1 Introduction 6 5.1 Warning 23

1.2 Clearances around the appliance 6 5.2 Delivery 23

1.3 Operating safety checks to protect 6 5.3 Unpacking of boiler 23
your appliance (checking the system 5.4 Positioning of the boiler 23
pressure) 5.5 Optional extras 24

1.4 Appliance status indicators 7 5.6 Plume management kit 25

1.5 Digital display 7 5.7 Installing the appliance for rear flue 26

1.6 Boiler value 7 outlet

1.7 Diagnostic 7 5.8 Installing the appliance for side flue 26
outlet

2 General layout 8 5.9 Completing horizontal flue installation 29

2.1 Operating scheme 9 5.10 Intake and exhaust terminal 29

2.2 Introduction 10 components

2.3 Description of control system and 10 5.11 In-line flue bend and flue extension 29

sequence of operation 5.12 Vertical flue instructions 30

2.4 Operating mode 10 5.13 Installation instructions for twin flue 32

2.5 Central heating mode 10 pipe

2.6 General function 10 5.14 Twin flue instructions 32

2.6 Safety device 10 5.15 Exhaust / suction system with 33

2.7 Overall dimension 11 concentric pipes for flat or sloping

2.8 Available pump head 11 roofs.

2.9 Pressure drop across appliance 11 Extensions with two separate pipes

5.16 Exhaust / suction system with two 33

3 Technical data WH System 3-20 12 separate rated 80 dia. pipes
natural gas exhaust on flat or sloping roof, suction

3.1 Technical data WH System 3-20 LPG 13 from vertical wall

3.2 Technical data WH System 4-24 14 5.17 Exhaust / suction system with two 33

natural gas separate pipes through a single

3.3 Technical data WH System 4-24 LPG 15 vertical wall

5.18 Installation instructions for 80/125 34

4 General requirements 16 concentric flue system

4.1 Safety 16 5.19 Assemble boiler 35

Gas safety (Installation and use) 5.20 Fitting valve pack 35

4.2 General information 16 5.21 Gas connection 35

4.3 Location of boiler 17 5.22 Central heating connection 35

4.4 Clearances around the appliance 17 5.23 Position of water/gas connections 35

4.5 Important notice 17 5.24 Safety valve discharge 36

4.6 Gas supply 17 5.25 Condensate drain connection 36

4.7 Flue system 18 5.26 Converting the appliance to different 37

4.8 Air supply 18 gas types

4.9 Water circulation (central heating) 18 5.27 Electrical connections 37

4.10 Flue terminal position 19 5.28 Outdoor sensor 37

4.11 Pipework 20

4.12 Boiler interlock control 20 6 Commissioning 38

4.13 Draining tap 20 6.1 Gas supply installation 38

4.14 Air release points 21 6.2 Electrical installation 38

4.15 Mains water feed: central heating 21 6.3 Initial filling of the system 38

4.16 Permissible methods of filling 21 6.4 Setting the heating system 38

4.17 Sizing of additional expansion vessel 22 design pressure

4.18 Installation to an existing central 22 6.5 Lighting the boiler 39

heating system 6.6 Check the gas pressure 39

4.19 Water treatment 23 6.7 Combustion check 39

4.20 Hard water areas 23 6.8 Checking the flue system 40

4.21 Electrical supply 25 6.9 Checking the heating thermostat 40

4

Sections Page

6.10 C.H. high/low temperature 40

6.11 Range rating central heating 40

6.12 Test mode 40

6.13 Instructing the user 41

7 Servicing instructions 41

7.1 Boiler frost protection 42

7.2 To inspect and clean the appliance 42

8 Replacements of parts 43

8.1 General 43

8.2 To remove front panel 43

8.3 To remove left and right panels 43

8.4 To remove/replace spark igniter box 43

8.5 To remove/replace fan 44

8.6 To remove/replace the electrodes 44

8.7 To remove/replace the burner 44

8.8 To remove/replace the heat 44
exchanger

8.9 To remove/replace expansion 45
vessel

8.10 To remove/replace gas valve 45

8.11 To remove/replace the water 45
pressure transducer

8.12 To remove/replace safety relief valve 45

8.13 To remove/replace pump 46

8.14 To remove/replace automatic air vent 46

8.15 To remove/replace C.H. flow and 46
return sensors

8.16 To remove/replace flue sensor 46

8.17 To clean and remove/replace 46
condensing trap

8.18 To remove panel control box 47

8.19 To remove the instrument panel 47

8.20 To remove/replace control board 47

8.21 To remove/replace digital display 47
board

8.22 External control connection 47

9 Fault finding 48

10 Electrical system diagram 49

11 Spare parts 50

12 Benchmark commissioning 55
checklist details

12.1 Analyser check list 60

5

A minimum bottom clearance of 80mm 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
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.

Top clearance:

The top clearance should be a minimum of
125mm.

Bottom clearance:

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

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

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

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

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
has been designed to supply your Central Heating and
hot water with separate indirect hot water storage cylinder
is also incorporated in the system.
The system boilers which incorporates a circulation pump,
expansion vessel, safety valve, pressure gauge and
electronic ignition.

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.

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 80mm is

USER CONTROLS

This appliance is designed to operate with the minimum

Before lighting the appliance check that the

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

2 - Water pressure: Shows the current
pressure in the system.
3 - Heating: When there is a demand for heating, icon
3 will be fl ashing.

Use the arrow up and the arrow down

buttons, (item 3 and

1.7 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.

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.

KEY :

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,
alternatively the system water pressure.

1 - ON/OFF button
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 central heating
outlet 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.
Press the arrow up or the arrow down buttons
to increase or decrease the temperature.

1.5 DIGITAL DISPLAY

KEY

1 - ON/OFF: When the appliance is ON
icon 7 is displayed.
2 - Water pressure: Shows the current
pressure in the system.
3 - Heating: When there is a demand for heating, icon
3 will be fl ashing.
4 - Anomaly - Lock - out - Test function.
5 - Temperature.
6 - Modulation fl ame level: When the burner is
lit, 3 different levels on icon 8 are displayed.

Fig. 1

6 - Press to show the boiler values.
Use the arrow up and arrow down buttons to select
the following information:
PBAR: water pressure
SFAN: speed fan (the display shows 3 digits
(e.g. 500 = 5000 rpm)
TFLOW: fl ow temperature
TRET: return temperature
PWR: % power of modulation.

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

- BOIL: It is possible to set the boiler parameters:
C.H. max fan speed
C.H. High/Low temperature: “1” high/“2” low.

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
PWR: % power of modulation.

Fig. 2

1.7 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.

7

2.0 GENERAL LAYOUT (Fig. 3)

KEY

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

7 - Control board
8 - Safety pressure relief valve
9 - CH return
10 - Circulation pump

1 1 - Automatic air vent
12 - Condensate drain
13 - Expansion vessel
14 - Heat exchanger
15 - Spark electrode
16 - Sensing electrode
17 - Flue temperature sensor
18 - Spark igniter
19 - Fan
20 - Burner

Fig. 3

21 - Manual air vent
22 - Overheat cut off thermostat
23 - CH flow sensor
24 - CH return sensor

8

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 - Gas valve
21 - Gas service cock
22 - CH compression ball valves

9

2.2 INTRODUCTION

2.3

DESCRIPTION OF CONTROL SYSTEM

AND SEQUENCE OF OPERATION

2.4 Operating mode

If the appliance is in demand for heat to

supply radiators, etc. , with the heating
circuit fully cha

external timer if required. The

An overheat cut off thermostat acts to turn

off the burner to resettable “lockout”.

Y our White Boiler Company Condensing Low
Nox has been designed to supply your
Central Heating and hot water where a
separate indirect hot water storage cylinder is
also incorporated in the system.
The system boilers which incorporates a
circulation pump, expansion vessel, safety
valve and electronic ignition.

2.3
AND SEQUENCE OF OPERATION

2.4 Operating mode

DESCRIPTION OF CONTROL SYSTEM

2.6 SAFETY DEVICE
In central heating, 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.

An overheat cut off thermostat acts to turn
off the burner to resettable “lockout”.
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

fi tted on heating circuit, to prevent the boiler

operating below this boiler system pressure.

If the appliance is in demand for heat to

supply radiators, etc. , with the heating
circuit fully charged above 1 bar, the boiler
will begin the ignition sequence and ignite.

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 .

2.5 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.

10

2.7 OVERALL DIMENSION
(Fig. 5)

Fig. 5

2.8 AVAILABLE PUMP HEAD
(Fig. 6)

2.9 PRESSURE DROP ACROSS
APPLIANCE (Fig. 7)

Fig. 6

Fig. 7

11

3 TECHNICAL DATA

WH SYSTEM 3-20

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

3

/h

FAN SPEED Max 4200 rpm - 140 Hz Combustion % CO

: 9.0 (+ 0.5 / - 0.5) Case ON

2

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 25 kg
WATER CONTENT 0.8 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
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
MINIMUM FLOW RATE C.H. 350 I/h
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required)
DESTINATION: GB, IE CATEGORY II
FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

2H3P

A IP X4 D

12

3.1 TECHNICAL DATA

Combustion

WH SYSTEM 3-20

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 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 25 kg
WATER CONTENT 0.8 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
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
MINIMUM FLOW RATE C.H. 350 I/h
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required)
DESTINATION: GB, IE CATEGORY II
FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

2H3P

A IP X4 D

13

3.2 TECHNICAL DATA

TABLE 3/C WH SYSTEM 4-24

NATURAL GAS (G 20) П2H3P

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

NOMINAL HEAT OUTPUT 23.9 kW
NOMINAL HEAT OUTPUT CONDENSING 26.4 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

3

/h

FAN SPEED Max 4200 rpm - 140 Hz Combustion % CO

: 9.0 (+ 0.5 / - 0.5) Case ON

2

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 26 kg
WATER CONTENT 0.8 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
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
MINIMUM FLOW RATE C.H. 350 I/h
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required)
DESTINATION: GB, IE CATEGORY II
FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

2H3P

A IP X4 D

14

3.3 TECHNICAL DATA

TABLE 3/D WH SYSTEM 4-24

LPG (G 31) П2H3P

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

NOMINAL HEAT OUTPUT 23.9 kW
NOMINAL HEAT OUTPUT CONDENSING 26.4 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 m

INLET PRESSURE G31 37 mbar G30 28-30 mbar
FAN SPEED 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)

3

/h

3

/h

DRY WEIGHT 26 kg
WATER CONTENT 0.8 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
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
MINIMUM FLOW RATE C.H. 350 I/h
FLUE OUTLET NOM. DIAMETER 100 mm specially supplied with boilers (If required)
DESTINATION: GB, IE CATEGORY II
FLUE TYPE - C13 - C33 - C53 NOX 5 SEDBUK

2H3P

A IP X4 D

15

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

APPLICABLE 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 System
3-20/4-24 system boiler has been tested and

examined by CERTIGAZ, and is certified to
comply with PrEN 483.

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

16

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

system 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 System
3-20/4-24 system 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.

3-20/4-24
and vertical wall capable of adequately
supporting the weight of the boiler and any
ancillary equipment.
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.

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

Bottom clearance:
A bottom clearance of 80mm is required

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

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

system boiler must be fitted on a flat

wall 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
system 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 System 3-20/4-24 system
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
(22mm) min to within at least one metre of
the boiler, (15mm) 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

17

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 metres high. The part number is

PRO110100.

Fit only recommended

FLUE TERMINAL

GUARD

times.

mbar across the installation pipework, it can be
assumed that a minimum permitted operating
pressure of 18mbar (nat gas) 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 metres high. The part number is

PRO110100.

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. [phone]

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.

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.

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)

18

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.

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.

4.10 FLUE TERMINAL POSITION

19

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
I/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 system 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

insitu, 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

20

Fig.6

4.14 AIR RELEASE POINTS

7 L 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 L 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 L 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 L of expansion water

Fig.7

Fig.8

4.16 PERMISSIBLE METHODS OF FILLING
Figure depicts the requirements of Diagram

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

21

If the capacity of the central heating system
should exceed 110 L, 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.

Reference should be made to British Gas

If the capacity of the central heating system
should exceed 110 L, 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

0.0833 0.140 0.259 0.551 0 .109 0.190 0.412 0.156 0.331

1/2” in BSP nominal size and be in accordance
with BS 2879.

4.18 INSTALLATION TO AN EXISTING CENTRAL

HEATING SYSTEM

The system 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 system boiler to
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.

22

.
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.

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

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:

-

1-15mm gas service valve

- 2-22mm compression ball valves

complete with 3/4” washers

- 2 fi xing bolts and wall plugs

5 INSTALLATION

This boiler has an aluminium 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

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 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.

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.

manufacturer’s instructions.

with a

The supply must be fused at 3 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

- 2 fi xing bolts and wall plugs

IMPORTANT NOTES:

The appliance carton contains:

a) Boiler fully assembled with fl ue adaptor

1-15mm gas service valve

- 2-22mm 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

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.

Fig.9

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.

23

(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):

52 - Self-cutting joint securing screw
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

Flue Diameter 60/100 80/125 60/100 80/125 80 mm

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

(concentric) (concentric) (concentric) (concentric) single pipe

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

1

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

24

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

25

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 inner 60 mm
diameter of 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 locating it onto 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 and fix securing screw.

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 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

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

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

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 inner 60 mm
diameter of 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).

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

Extensions must be installed with the widened

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

IMPORTANT:
Inline 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
(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 the wall.

-

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

the

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

g.14.

Insert the plastic expansion

dia. hole in 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.

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).

Each extension length extends the pipe by

Insert the flue assembly locating it onto the

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 and fix securing screw.

Fit the terminal rubber wall seal and if

Extension kits are available to order for flue

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

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

diameter of 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).

Important: Make sure that the inner 60 mm

26

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 5 mm as the
side panels.

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.

27

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 5 mm as the
side panels.

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

28

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 and fix securing screw.

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

5.10 INTAKE AND EXHAUST TERMINAL COMPONENTS

Fig 16

Fig.17

KEY

52 - Self-cutting joint securing screw

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

60 - Fumes sample point

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

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).

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

52 - Self-cutting joint securing screw

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

29

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 10mm 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

30

Fig. 20

Straight Flue Straight Flue Offset Flue Offset Flue
L = 12 m Max L = 12 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 10mm 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 inner 60

mm diameter of 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 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

52 - Self-cutting joint securing screw

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.

31

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

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

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 System 3-20/4-24 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 to ensure the maximum

flue length is not exceeded.

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 125mm

(5 in) diameter flashing plate will be required.

32

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 metres + Terminal
Minimum distance: L = 0.5 + 0.5 = 1 metre + 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

5.17

Exhaust/suction system with with two separate
rated 80 dia. pipes exhaust on fl at or sloping roof,
suction from vertical wall (fi g. 25).

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

Exhaust/suction system with two separate
pipes through a single vertical wall (fi g. 26).

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

Fig. 26

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

Available on request from:
THE WHITE BOILER COMPANY

Chartists way, Morley, Leeds, West Yorkshire
ENGLAND LS27 9ET - U.K.
Tel: [phone]

33

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: [phone]

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 = 25m Max L = 25m Max L = 20m Max L = 22.5m 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: [phone]

TEG060050 Flashing sleeve/slate

34

5.19 ASSEMBLE BOILER

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

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

(Also see section 4.6)

Important consult (sect 4.6).

5.22 CENTRAL HEATING CONNECTION

(Fig. 29)
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.

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.

- 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

5.23 POSITION OF WATER/GAS CONNECTIONS

Fig. 30

35

5.24 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.

5.25 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

36

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

5.26 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.

5.27 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

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 it should
take the cable slip from the anchorage until
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).

5.28 OUTDOOR SENSOR
For use, consult Outdoor Sensor

instructions.

8.2.

37

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

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

6.4 SETTING THE HEATING SYSTEM DESIGN
PRESSURE

The design pressure must be min. 1bar 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.

GAS VALVE

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.

Connecting the external switch live.
To create a demand the boiler requires a

230V switch live from the external controls.
This switch live simply needs connecting to
the connection on the bottom left side of the
PCB housing. (see system diagram fig. 55
and fig. 38).

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 when the
water is clear, free of bubbles and flows
out. In the same way release air from any
high points in the pipework.

-

Continue filling the system until 1.5 bar
register on digital display.
button once again to return to the main
screen.
Then turn off the filling points stopcock.

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

Press the P

Fig. 35

Fig. 36

Fig. 38

38

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

IMPORTANT:

Before lighting the boiler select the minimum

heating temperature (see section 1.4 key 5).
This must be left at minimum for approx 5 mins
to purge air safely from the boiler.

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.

- 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.

6.6 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).
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).

carrying out a combustion

measurement should have been assessed

6.7

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.

It is essential that this test is repeated

with the casing on as this will check the

integrity of the flue.

6.5 LIGHTING THE BOILER

6.7

COMBUSTION CHECK

Before lighting the boiler make sure that the

heating circuit flow and return valves are open.

- Ensure all external controls are calling for
heat.

- To select the minimum heating temperature

press the radiator button.

IMPORTANT:

Before lighting the boiler select the minimum

heating temperature (see section 1.4 key 5).
This must be left at minimum for approx 5 mins
to purge air safely from the boiler.

-

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.

- 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.

6.6 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).
With leak detection fluid test for gas tightness

of all gas components and joints.

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

IMPORTANT:

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

Unscrew the test sample screw on the boiler

corresponding value in table 10 and with

Check all gas carrying components along

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

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.

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

reference to page 63.

. Check the reading against the

2

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

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/Ͳ0.5)
LPG 10.5(+0.5/Ͳ0.5)

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.

39

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).

6.10 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).

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:

- 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 C.H. 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.
Press reset to esc test mode.

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.

ELECTRODES POSITION

Fig. 38

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

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

6.9 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).

6.10 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.

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).

The boiler comes set, in Central heating,

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

- Press enter and reset buttons (item 1

sec 1.5 key 5 to set heating

6.11 RANGE RATING CENTRAL HEATING

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.

strictly in the sequence indicated, by
qualified personnel only.

To check max fan speed, see tables 11:

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.

(item 3 and 4 fig. 1) to select the
followings options:

- PM1 C.H. max fan speed.

The adjustment to fan speed must be

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

- Use arrow up and arrow down buttons

been adjusted by the

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

6.12 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.
Press reset to esc test mode.

the arrow up and the

TABLE 11

Range rating regulation of Central Heating

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

Maximum setting 20 24,5 4200 4200

Minimum setting 3,7 4,1 1300 1300

WH System 3-20 WH System 4-24 WH System 3-20 WH System 4-24

40

RATIO BETWEEN FAN SPEED AND HEAT INPUT

6.13 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.

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

(Refer to

table 10 and page 59).

- 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

6.13 INSTRUCTING THE USER

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

- To the Householder explain his/her

After completion of the installation and

responsibilities under the “Gas Safety
Regulations 2000”.

- Explain and demonstrate the lighting
and shutting down procedures.

- 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
necessary to prevent damage to the
system, and to the building, in the
event of the system remaining
inoperative during frost conditions.

-

Explain the func tion and t he use of the

boiler, the summer/winter button, the

ON/OFF switch and th e reset of the

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.

SERVICING INSTRUCTIONS

7

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.

Combustion testing must be carried out by competent person

using a combustion analyser conforming to BS7927.

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 59).

- 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.

41

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

7.1 BOILER FROST PROTECTION

The appliance has a built in frost protection
device that protects the boiler from freezing.
With the gas and electric supplies ON and
irrespective of any room thermostat setting, the
frost protection device will operate the pump
when the temperature 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.

- IMPORTANT:
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
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.

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.

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

It is essential that a good seal is made at

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.

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

42

8 REPLACEMENT OF PARTS

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 FRONT PANEL
(Fig. 39)

To remove the front panel unscrew the two

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

Remove the front panel (fig. 39).

Unscrew the four screw to the bottom

panel.
Unscrew the two screws to the side panel
and pull.

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.

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

Fig.39

8.2 TO REMOVE THE FRONT PANEL
(Fig. 39)

To remove the front panel unscrew the two

8.3 TO REMOVE LEFT AND RIGHT PANELS
(Fig. 39)

Unscrew the four screw to the bottom

8.4 TO REMOVE/REPLACE SPARK

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

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

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..

Remove the front panel (fig. 39).
panel.

Unscrew the two screws to the side panel
and pull.

control box.
igniter to the bracket.

Fig.40

Fig.41

43

8.5 TO REMOVE/REPLACE FAN

the retaining clip. Detach the connectors
from the fan.
Unscrew the four screws 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).

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

(Fig. 42)
Remove the front panel (fig. 39).

Unscrew the gas pipe nut and remove
the retaining clip. Detach the connectors
from the fan.
Unscrew the four screws 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).

8.6 TO REMOVE/ REPLACE THE
ELECTRODES (Fig.37)

Remove the 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.

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

Remove the front panel (fig. 39).

Unscrew the gas pipe nut and remove the
retaining clip. Detach the connectors from

Unscrew the screws to the burner cover
To remove the burner, unscrew the screws

in the lower cover side.
Replace in reverse order (always fitting a

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).

the fan.
and remove the cover with the fan.

new gasket).

Fig.42

8.8 TO REMOVE/REPLACE THE HEAT
EXCHANGER

Remove the front and bottom panels
(fig. 39-40).

Close the on/off valves for the heating

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

Loosen the four heat exchanger securing

screws and clamps then carefully ease the
heat exchanger out.

Follow the instructions to 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.

CAUTION : There will be water in the heat

exchanger.
Replace in reverse order, always use new

O-ring seals.

44

Fig.43

8.9 TO REMOVE/REPLACE EXPANSION

Unscrew the nut and the four screws on

the bottom of the gas valve.

Replace in reverse order.

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.

VESSEL (Fig.44)

Remove the front and bottom panels
(fig. 39-40).
Close the on/off valves for the heating
circuit and drain the water at the drain
point (fig.36). 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 the 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).

Fig.44

8.11 TO REMOVE/REPLACE THE WATER
PRESSURE TRANSDUCER (Fig. 46)

Remove the 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.

8.12 TO REMOVE/REPLACE SAFETY
RELIEF VALVE (Fig. 46)

Remove the 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.

Fig.45

Fig.46

45

8.13 TO REMOVE/REPLACE PUMP (Fig.47)

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.

8.15 TO REMOVE/REPLACE C.H. FLOW AND

RETURN SENSORS (Fig. 48)

Detach the wire connector and remove

the retaining cli

the 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

Remove the 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:

8.14 TO REMOVE/REPLACE AUTOMATIC
AIR VENT (Fig. 47)

Remove the front and bottom panels

(fig. 39-40).

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

remove the securing clip at the pump

manifold.

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.

the supply wire connector from the

Always use new O-ring.

Fig.47

8.15 TO REMOVE/REPLACE C.H. FLOW AND

RETURN SENSORS (Fig. 48)

Remove the 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).

8.16 TO REMOVE/REPLACE FLUE SENSOR

(Fig. 3 item 22)

Remove

Detach the wire connector and rotate the

sensor.
Replace in reverse order.

8.17 TO CLEAN AND REMOVE/REPLACE
CONDENSING TRAP (Fig. 49)

Remove the

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 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.

the front panel (fig. 39).

front panel (fig. 39), bottom

Fig.48

Fig.49

46

818 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

the

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

52).

8.20 TO REMOVE/REPLACE CONTROL
BOARD (Fig.54).

Remove the 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. 54).

8.21 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.

8.22 EXTERNAL CONTROL CONNECTION
(Fig. 53)

Remove the front panel (fig. 39).
Connect the external control connection
to switching wire.

(Fig. 50,51,52).
Remove the

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. 52).
This will allow free access to lower part
of the boiler.

front panel (fig. 39).

Fig.51

Fig.50

Fig.52

8.19 TO REMOVE THE INSTRUMENT PANEL
(Fig. 53).

Remove

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

52).

8.20 TO REMOVE/REPLACE CONTROL
BOARD (Fig.54).

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. 54).

8.21 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).

Remove the front panel (fig. 39).

the

front panel (fig. 39).

8.22 EXTERNAL CONTROL CONNECTION
(Fig. 53)

Connect the external control connection
to switching wire.

Remove the front panel (fig. 39).

Fig.53

Fig.54

47

9 FAULT FINDING

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, 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:

48

10 ELECTRICAL SYSTEM DIAGRAM

Fig. 55

49

11 SPARE PARTS

50

Fig. 56

THE WHITE BOILER COMPANY WH SYSTEM 3-20/4-24

HIGH EFFICIENCY CONDENSING COMBINATION BOILER

SHORT LIST OF SPARE PARTS AND FLUE ACCESSORIES

Pos. Part. No. G.C.

Part. No.

1 CIR150100 Digital display WH System 3-20/4-24
2 PAN150200 Instrument panel WH System 3-20/4-24

3 CIR150070 Control board
4 SCA110051 Instrument panel box
5 FUS010150 Internal fuse 3.15 A
6 CIR130100 Switching wire board
7 TRA150100 Water pressure transducer
8 FOR150250 Water pressure transducer clip

9 GRU150150 System return manifold
10 TUB150550 System by-pass pipe
11 GRU150080 System fl ow manifold
12 VAL150250 Drain valve
13 VAL150100 Safety relief valve
14 5018025 1/2” gasket
15 TUB150480 Safety relief valve pipe
16 5018030 3/4”gasket
17 TUB150150 Gas valve inlet pipe
18 TUB150500 Flow pipe
19 SON110100 C.H. fl ow and return sensors
20 ORI150100 Heat exchanger O-ring
21 FOR150050 Heat exchanger clip
22 TER080050 Overheat thermostat (TER060150)
23 VAL150200 Manual air vent
24 TUB110150 Flexible condensing pipe (TUB110300)
25 RAC110050 Condensing trap
26 FAS150050 Condensing trap pipe hose clamp 12-22
27 TUB150050 Condensing pipe
28 FAS150150 Condensing trap hose clamp 30-45
29 GUA010260 3/4” gas valve gasket
30 VAL150150 Gas valve
31 TUB150200 Gas valve outlet pipe
32 RAC150050 Air/gas mixer junction
33 ORI150050 Air/gas mixer junction O-ring
34 FOR150100 Air/gas mixer junction clip
35 MIX150050 WH System 4-24 air/gas mixer
36 MIX150100 WH System 3-20 air/gas mixer
37 ORI110050 Air/gas mixer - fan O-ring
38 VEN130100 Fan
39 GUA110052 Fan - burner gasket
40 CAN150100 Sensing electrode
41 CAN150070 Spark electrode
42 GUA150050 Sensing/spark electrode gasket

Description

(GUA010200)

(GUA010250)

(SON110150)

51

Pos. Part. No. G.C.

Description

Part. No.

43 GUA150100 WH System 4-24 burner gasket

43.1 GUA150120 WH System 3-20 burner gasket
44 BRU150050 WH System 3-20 burner

44.1 BRU150100 WH System 4-24 burner
45 FLA110050 Flue fl ange

(FLA110052)

46 GUA110350 Flue fl ange gasket
47 GUA110250 Flue manifold washer (GUA130050)
48 SON130050 Temperature fl ue sensor
49 GEN150100 Spark igniter
50 COL150050 Flue exhaust manifold
51 SCA150050 WH System 3-20 heat exchanger

51.1 SCA150100 WH System 4-24 heat exchanger
52 VAS150050 Expansion vessel
53 GUA050050 3/8” gasket

(GUA060111)

54 TUB150120 Expansion vessel pipe
55 GUA010050 1/4” gasket

56 TUB150110 Return pipe
57 GUA010310 1” gasket

(GUA010311)

58 CIR150100 Pump
59 ORI150150 Pump O-ring
60 FOR150200 Pump clip
/ IMP150100 WH System 3-20/4-24 wiring harness

52

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

53

THE WHITE BOILER COMPANY

A Ravenheat Group Company

Chartists Way, Morley, Leeds, U.K. LS27 9ET

Telephone: [phone]
Fax: [phone]
Website: www.ravenheat.co.uk
E-mail: [e-mail]

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.

54

COD 0017LIB15010/0 07/2015

BENCHMARK COMMISSIONING CHECKLIST DETAILS

12

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: [phone]
fax: [phone]
e-mail: [e-mail]

55

56

57

Benchmark Commissioning and
Servicing Section

It is a requirement that the boiler is installed and commissioned to the
manuIacturers 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 %enchmarN 6erYice InterYal
5ecord and left with the householder.

58

www.centralheating.co.uk

© Heating and Hotwater Industry Council (HHIC)

FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO

CHECK ON COMMISSIONING A CONDENSING BOILER

59

12.1 ANALYSER CHECK LIST

60

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.

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:Kat inKiEitor Zas used" 4uantit\ litres
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CENTRAL HEATING MODE measure and record
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COMBINATION BOILERS ONLY

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CONDENSING BOILERS ONLY

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61

SERVICE RECORD

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
Service Provider

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