VOKERA ProCombi 85 HE, ProCombi 100 HE Installation And Service Instructions Manual
Supplied By www.heating spares.co Tel. 0161 620 6677
Installation & Servicing Instructions
THESE INSTRUCTIONS
TO BE RETAINED
BY USER
0694
Supplied By www.heating spares.co Tel. 0161 620 6677
Contents
Design principles and operating sequence Page
1.1 Principle components 4
1.2 Mode of operation (at rest) 4
1.3 Mode of operation (heating) 4
1.4 Mode of operation (DHW) 4
1.5 Safety devices 4
Technical data Page
2.1 Central heating 5
2.2 Domestic hot water 5
2.3 Gas pressure 5
2.4 Expansion vessel 5
2.5 Dimensions 5
2.6 Clearances 5
2.7 Connections 5
2.8 Electrical 5
2.9 Flue details 5
2.10 Efficiency 5
2.11 Pump duty 6
2.12 Appliance 6
General requirements (UK) Page
3.1 Related documents 7
3.2 Location of appliance 7
3.3 Gas supply 7
3.4 Flue system 7
3.5 Air supply 7
3.6 Water circulation 7
3.6.1 Pipework 8
3.6.2 Automatic by-pass 8
3.6.3 Drain cocks 8
3.6.4 Air release points 8
3.6.5 Expansion vessel 8
3.6.6 Filling point 8
3.6.7 Low pressure sealed system 8
3.6.8 Frequent filling 8
3.7 Electrical supply 8
3.8 Showers 8
3.9 Mounting on a combustible surface 9
3.10 Timber framed building 9
3.11 Inhibitors 9
Installation Page
4.1 Delivery 10
4.2 Contents 10
4.3 Unpacking 10
4.4 Preparation for mounting the appliance 10
4.5 Fitting the flue 10
4.5.1 Concentric horizontal flue 10
4.5.2 Concentric vertical flue 11
4.6 Connecting the gas and water 12
4.6.1 Gas 12
4.6.2 Flow and return 12
4.6.3 Cold water inlet 12
4.6.4 Hot water outlet 12
4.6.5 Safety valve 12
4.6.6 Condense pipe 12
4.7 Electrical connections 13
4.7.1 Casing removal 13
4.7.2 Appliance terminal block 13
4.7.3 Connecting the mains (230V) input 13
Commissioning Page
5.1 Gas supply installation 14
5.2 The heating system 14
5.3 Initial filling of the system 14
5.4 Initial flushing 14
5.5 Filling the hot water system 14
5.6 Pre-operation checks 14
5.7 Initial lighting 14
5.7.1 Checking burner pressures 14
5.8 Final flushing of the heating system 14
5.8.1 Inhibitors 14
5.9 Setting the boiler operating temperature 14
5.9.1 Setting the DHW temperature 15
5.10 Setting the system design pressure 15
5.11 Regulating the hot water 15
5.11.1 Changing the flow restrictor 15
5.11.2 Regulating the central heating system 15
5.12 Final checks 15
5.13 Instructing the user 15
5.14 Technical assistance 15
Servicing instructions Page
6.1 General 16
6.2 Routine annual servicing 16
6.3 Replacement of components 16
6.4 Component removal procedure 16
6.5 Pump assembly 16
6.6 Safety valve 16
6.7 Automatic air release valve 16
6.8 Water pressure switch 17
6.9 Pressure gauge 17
6.10 Primary thermistor 17
6.11 High limit thermostat 17
6.12 PCB 17
6.13 Gas valve 17
6.14 Integral time switch 18
6.15 Electrode, burner thermostat, burner & injectors 18
6.16 Flue fan 18
6.17 Main heat exchanger 19
6.18 Air pressure switch 19
6.19 Flow restrictor 19
6.20 DHW flow switch 19
6.21 DHW heat exchanger 20
6.22 Valve actuator 20
6.23 Divertor valve cartridge 20
6.24 DHW thermistor 20
6.25 Automatic by-pass 20
6.26 DHW non-return valve 2 0
6.27 Expansion vessel 20
6.27.1 Expansion
6.27.2 Expansion vessel removal
6.28.1 Latent heat collector 21
6.28.2 Dismantling the latent heat collector 21
6.29 Condense trap removal 21
Checks, adjustments and fault finding page
7.1 Checking appliance operation 22
7.2 Appliance mode of operation 22
7.2.1 Selector switch in the OFF position 22
7.2.2 Selector switch in the hot water only position 22
7.2.3 Selector switch in the heating & hot water position 22
7.2.4 Appliance functions 22
7.2.5 DHW mode 22
7.2.6 Heating mode 23
7.3 Checking & adjusting burner pressure 24
7.3.1 Setting the maximum burner pressure 24
7.3.2 Setting the minimum burner pressure 24
7.3.3 Setting the minimum CH output 24
7.4 Combustion analysis test 24
7.5 Checking the expansion vessel 25
7.6 External faults 25
7.6.1 Installation faults 25
7.7 Electrical checks 25
7.7.1 Earth continuity test 25
7.7.2 Short circuit check 25
7.7.3 Polarity check 25
7.7.4 Reversed polarity or supply fault 26
7.7.5 Resistance to earth check 26
7.8 Fault finding 26
7.8.1 Replacing the main PCB 26
7.9 Fault codes 26
7.10 Fault finding 27-32
Wiring diagrams Page
8.1 External wiring 33
8.2 Typical control applications 33
8.3 Room thermostat 33
8.4 Other controls 33
Functional diagram 3 4
L.P.G. instructions Page
10.1 Related documents 35
10.2 Technical data 35
10.3 Converting the appliance gas supply 35
10.4 Gas supply 35
10.5 Gas supply installation 35
10.6 Checking & adjusting burner pressure 35
10.6.1 Setting the maximum burner pressure 35
10.6.2 Setting the minimum burner pressure 3 5
vessel removal (with sufficient clearance above)
(with insufficient clearance above)
21
20
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INTRODUCTION
The PRO Combi HE range of appliances is comprised of
2 models of high-efficiency combination boiler with inputs
to heating & DHW of 25, 29 kW respectively. Each appliance - by design - incorporates electronic ignition, circulating pump, expansion vessel, safety valve, pressure
gauge and automatic by-pass.
The PRO Combi HE range is produced as room sealed,
category II2H3P appliances, suitable for internal wall
mounting applications only. They are provided with a fan
powered flue outlet with an annular coaxial combustion air
intake that can be rotated - horizontally - through 360
degrees for various horizontal or vertical applications. The
PRO Combi HE range is approved for use with C12 & C32
type flue applications.
These appliances are designed for use with a sealed
system only; consequently they are not intended for use
on open vented systems
Fig.1 General Layout
1 Discharge valve
2 Gas valve
3 Modulator coil
4 Pressure switch
5 Condense trap
6 Ignition transformer
7 Expansion vessel
8 Electrode
9 Main burner
1 0 Main heat exchanger
1 1 Latent heat collector
1 2 Flue gas analysis test point
1 3 Flue outlet
1 4 Air intake
1 5 Differential pressure switch
1 6 Silicone pressure tube (-)
1 7 Silicone pressure tube (+)
1 8 Fan assembly
1 9 CH NTC sensor
2 0 High limit thermostat
21 Combustion chamber
22 Condensate pressure switch
2 3 Auto air vent (AAV)
24 Pump
2 5 DHW flow switch
26 DHW sensor
2 7 Domestic hot water heat exchanger
2 8 Diverter valve motor
29 Pressure gauge
30 DHW position
3 1 Mode selector switch
3 2 Fault indicator led
33 CH position
34 Timeclock
Fig. 1
29 30 31 33
32
34
3
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SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE
1.1 PRINCIPLE COMPONENTS
● A fully integrated electronic control board fea-
turing electronic temperature control, anti-cycle control, pump over-run, LED fault indicator,
full gas modulation.
● Low-water-content, copper heat exchanger.
● Electronic ignition with flame supervision.
● Integral high-head pump.
● Fan.
● Air pressure switch.
● Expansion vessel.
● Water pressure switch.
● Two-stage gas valve.
● Pressure gauge.
● Safety valve.
● Condense switch.
1.2 MODE OF OPERATION (at rest)
When the appliance is at rest and there are no
requests for heating or DHW, the following functions are active:
● Frost-protection system: the frost-protection
system protects the appliance against the risk
of frost damage. Should the temperature of the
appliance fall to 5 °C, the boiler will function in
the heating mode at minimum power until it
reaches 35 °C.
● Anti-block function: the anti-block function ena-
bles the pump and divertor valve actuator, to be
energised for short periods, when the appliance has been inactive for more than 19-hours.
DHW
temperature
sensor
DHW non
return valve
Water
pressure
switch
Automatic
by-pass
Safety valve
Fig. 2
CH
flow
latent heat
collector
DHW
outlet
Flue
outlet
Gas valve
DHW heat
exchanger
Air
intake
Pressure
switch
Main heat
exchanger
return
CH NTC
sensor
Main
burner
CH
Expansion
vessel
AAV
Pump
Diverter
valve motor
DHW
flow switch
Domestic cold
water inlet
1.3 MODE OF OPERATION (Heating)
When there is a request for heat via the time clock
and/or any external control, the pump and fan are
started, the fan will then prove the air pressure
switch. At this point an ignition sequence is
enabled.
Ignition is sensed by the electronic circuitry to
ensure flame stability at the burner. Once successful ignition has been achieved, the electronic
circuitry increases the gas rate to 75% for a
period of 15 minutes. Thereafter, the boiler’s
output will either be increase to maximum or
modulate to suit the set requirement.
When the appliance reaches the desired temperature the burner will shut down and the boiler
will perform a three-minute anti-cycle (timer delay).
When the request for heat has been satisfied the
appliance pump and fan may continue to operate
to dissipate any residual heat within the appliance.
1.4 MODE OF OPERATION (DHW)
When there is a request for DHW via a hot water
outlet or tap, the pump and fan are started, the fan
will then prove the air pressure switch. At this
point an ignition sequence is enabled.
Ignition is sensed by the electronic circuitry to
ensure flame stability at the burner. Once successful ignition has been achieved, the electronic
circuitry increases the gas rate to maximum or
will modulate output to stabilise the temperature.
In the event of the appliance exceeding the
desired temperature the burner will shut down
until the temperature drops.
When the request for DHW has been satisfied the
appliance pump and fan may continue to operate
to dissipate any residual heat within the appliance.
1.5 SAFETY DEVICES
When the appliance is in use, safe operation is
ensured by:
● A water pressure switch that monitors system
water pressure and will deactivate the pump,
fan and burner should the system water pressure drop below the rated tolerance.
● A high limit thermostat that over-rides the tem-
perature control circuit to prevent or interrupt
the operation of the burner.
● An air pressure switch that requires the fan to
prove operation before the gas valve is energised.
● A pressure switch that interrupts the operation
of the appliance if the condense pipe becomes
blocked.
● A safety valve which releases excess pressure
from the primary circuit.
4
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SECTION 2 TECHNICAL DATA
85 HE
2.1 Central heating
Heat input (kW) 25.00 29.00
Maximum heat output@ 80/60 °C (kW) 24.35 28.30
Minimum heat output@ 80/60 °C (kW) 14.25 14.28
Maximum heat output@ 50/30 °C (kW) 25.90 29.93
Minimum heat output@ 50/30 °C (kW) 14.85 14.75
Minimum working pressure 0.5 bar 0.5 bar
Maximum working pressure 2.7 bar 2.7 bar
Minimum flow rate 350 l/h 350 l/h
2.2 Domestic hot water
Minimum output (kW) 9.50 9.90
Flow rate (35 °C rise) 10.2 l/min 11.9 l/min
Maximum inlet pressure 6.0 bar 6.0 bar
Minimum inlet working pressure 0.15 bar 0.15 bar
Minimum flow rate 2 l/min. 2 l/min.
2.3 Gas pressures
Inlet pressure G20 20.0 mbar 20.0 mbar
Maximum burner pressure 9.40 mbar 9.20 mbar
Minimum burner pressure (central heating) 3.50 mbar 2.70 mbar
Minimum burner pressure (domestic hot water) 1.50 mbar 1.20 mbar
Gross rate (central heating, max - min) 2.64 - 1.59 m3/h 3.07 - 1.59 m3/h
Injectors size 12 x 1.35 mm 14 x 1.35 mm
100 HE
2.4 Expansion vessel
Capacity 8 litres 10 litres
Maximum system volume 76 litres 91 litres
Pre-charge pressure 1.0 bar 1.0 bar
2.5 Dimensions
Height 780 mm 780 mm
Width 400 mm 450 mm
Depth 332 mm 332 mm
Dry weight 40 kg 44 kg
2.6 Clearances
Sides 12 mm 12 mm
Top 150 mm from casing or 25 mm above flue elbow, whichever is applicable
Bottom 150 mm 150 mm
Front 600 mm 600 mm
2.7 Connections
Flow & return 22 mm 22 mm
Hot & cold water connections 15 mm 15 mm
Gas 15 mm 15 mm
Safety valve 15 mm 15 mm
Condense 21 mm 21 mm
2.8 Electrical
Voltage 230V/~ 50hz 230V/~ 50hz
Power consumption 153 W 153 W
Internal fuse 2 A 2 A
External fuse 3 A 3 A
2.9 Flue details (concentric)
Maximum horizontal flue length (60/100mm) 4.5 m 4.0 m
Maximum vertical flue length (60/100mm) 5.5 m 5.0 m
2.10 Efficiency
SEDBUK 86.9 Band “B” 86.7 Band “B”
Ref. Condition 15 °C , 1013,25 mbar, dry gas
NOTE: L.P.G. data refer to section 10
5
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2.11 PUMP DUTY
Fig. 3 shows the flow rate available - after allowing for pressure loss through the appliance - for system
requirements. When using this graph, apply only the pressure loss of the system. The graph is based on a
20 ºC temperature differential.
85 HE - 100 HE
5,0
4,5
4,0
3,5
3,0
2,5
2,0
1,5
1,0
0,5
0,0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300
first speed
second speed
85 HE 100 HE
2.12 Appliance
NOx 94 ppm - 166 mg/kWh 92 ppm - 162 mg/kWh
CO (max-min) 80 ppm - 80 ppm 100 ppm - 60 ppm
CO2 (max-min) 6.75 - 3.90 % 7.05 - 3.50 %
CO/CO2 ratio (max) 0.001 to 1 0.001 to 1
CO/CO
ratio (min) 0.002 to 1 0.002 to 1
2
third speed
SECTION 3 GENERAL REQUIREMENTS
Fig. 4
Key Location Minimum distance
A Below an opening (window, air-brick, etc.) 300 mm
B Above an opening (window, air-brick, etc.) 300 mm
C To the side of an opening (window, air-brick, etc.) 300 mm
D Below gutter, drain-pipe, etc. 25 mm
E Below eaves 25mm
F Below balcony, car-port roof, etc. 25 mm
G To the side of a soil/drain-pipe, etc. 25 mm
H From internal/external corner or boundary 300 mm
I Above ground, roof, or balcony level 300 mm
J From a surface or boundary facing the terminal 1200 mm
K From a terminal facing a terminal 1200 mm
L From an opening in the car-port into the building 1200 mm
M Vertically from a terminal on the same wall 1500 mm
N Horizontally from a terminal on the same wall 300 mm
P From a structure to the side of the vertical terminal 500 mm
Q From the top of the vertical terminal to the roof flashing As determined by the fixed collar
of the vertical terminal
6
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This appliance must be installed by a competent
person in accordance with the Gas Safety (Installation & Use) Regulations.
3.1 RELATED DOCUMENTS
The installation of this boiler must be in accordance with the relevant requirements of the Gas
Safety (Installation & Use) Regulations, the local
building regulations, the current I.E.E. wiring
regulations, the bylaws of the local water undertaking, the Building Standards (Scotland) Regulation and Building Standards (Northern Ireland)
Regulations.
It should be in accordance also with any relevant
requirements of the local authority and the relevant recommendations of the following British
Standard Codes of Practice.
3.2 LOCATION OF APPLIANCE
The appliance 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, with respect to the installation of the appliance in a room
or internal space containing a bath or shower.
3. 3 GAS SUPPLY
The gas meter - as supplied by the gas supplier
- must be checked to ensure that it is of adequate
size to deal with the maximum rated input of all
the appliances that it serves. Installation pipes
must be fitted in accordance with BS 6891.
Pipe work from the meter to the appliance must
be of adequate size. Pipes of a smaller size than
the appliance gas inlet connection must not be
used. The installation must be tested for soundness in accordance with BS6891.
If the gas supply serves more than one appliance,
it must be ensured that an adequate supply is
maintained to each appliance when they are in
use at the same time.
3.4 FLUE SYSTEM
The terminal should be located where the dispersal of combustion products is not impeded and
with due regard for the damage and discoloration
that may occur to building products located nearby.
The terminal must not be located in a place where
it is likely to cause a nuisance (see fig. 4).
Water vapour will condense on leaving the terminal and the effect of such pluming must be
considered.
BS 5440 PART 1 FLUES
BS 5440 PART 2 FLUES & VENTILATION
BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS
BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES
(2ND FAMILY GASES)
BS 6798 INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60kW
BS 6891 LOW PRESSURE INSTALLATION PIPES
BS 7074 PART 1 APPLICATION, SELECTION AND INSTALLATION OF EXPANSION VESSELS AND
ANCILLARY EQUIPMENT FOR SEALED WATER SYSTEMS
When an appliance is installed in a room or internal
space containing a bath or shower, the appliance
or any control pertaining to it must not be within
reach of a person using the bath or shower.
The location chosen for the appliance must permit
the provision of a safe and satisfactory flue and
termination. The location must also permit an
adequate air supply for combustion purposes
and an adequate space for servicing and air
circulation around the appliance. Where the installation of the appliance will be in an unusual
location special procedures may be necessary,
BS 6798 gives detailed guidance on this aspect.
A compartment used to enclose the appliance
must be designed and constructed specifically
for this purpose. An existing compartment/cupboard may be utilised provided that it is modified
to suit.
Details of essential features of compartment/
cupboard design including airing cupboard installations are given in BS 6798. This appliance is not
suitable for external installation.
3.5 AIR SUPPLY
3.6 WATER CIRCULATION
If installed less than 2m above a pavement or
platform to which people have access (including
balconies or flat roofs) the terminal must be
protected by a guard of durable material. The
guard must be fitted centrally over the terminal.
Refer to BS 5440 Part 1, when a terminal is sited
less than 1m below a plastic gutter, or less than
500mm below a painted surface, a suitable one
metre long heat shield should be fitted.
The following notes are intended for general
guidance only.
This appliance is a room-sealed, fan-flued boiler,
consequently it does not require a permanent air
vent for combustion air supply.
When installed in a cupboard or compartment,
ventilation for cooling purposes is also not required.
Detailed recommendations are given in BS 5449
Part 1 and BS 6798. The following notes are for
general guidance only.
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3.6.1 PIPEWORK
It is recommended that copper tubing to BS 2871
Part 1 is used in conjunction with soldered capillary joints.
Where possible pipes should have a gradient to
ensure air is carried naturally to air release points
and that water flows naturally to drain cocks.
Except where providing useful heat, pipes should
be insulated to avoid heat loss and in particular to
avoid the possibility of freezing. Particular attention should be paid to pipes passing through
ventilated areas such as under floors, loft space
and void areas.
3.6.2 AUTOMATIC BY-PASS
The appliance has a built-in automatic by-pass.
However it may be necessary to fit an external
bypass should the design of the heating system
require such. In any case, the design of the
system should be such that it prevents boiler
‘cycling’.
3.6.3 DRAIN COCKS
These must be located in accessible positions to
facilitate draining of the appliance and all water
pipes connected to the appliance. The drain
cocks must be manufactured in accordance with
BS 2879.
3.6.7 LOW PRESSURE SEALED SYSTEM
An alternative method of filling the system would
be from an independent make-up vessel or tank
mounted in a position at least 1 metre above the
highest point in the system and at least 5 metres
above the boiler (see fig. 5a).
The cold feed from the make-up vessel or tank
must be fitted with an approved non-return valve
and stopcock for isolation purposes. The feed
pipe should be connected to the return pipe as
close to the boiler as possible.
Make-up vessel
or tank
Automatic
air-vent
Non-return
valve
Stopcock
5.0 metres minimum
3.6.4 AIR RELEASE POINTS
These must be positioned at the highest points in
the system where air is likely to be trapped. They
should be used to expel trapped air and allow
complete filling of the system.
3.6.5 EXPANSION VESSEL
The appliance has an integral expansion vessel
to accommodate the increased volume of water
when the system is heated. It can accept up to 8
litres (25kW) or 10 litres (29 kW) of expansion from
within the system, generally this is sufficient,
however if the system has an unusually high water
content, it may be necessary to provide additional
expansion capacity (see 6.19).
3.6.6 FILLING POINT
An approved method for initial filling of the system
and replacing water lost during servicing etc. is
required (see fig. 5). This method of filling must
comply with the current Water Supply (Water
Fittings) Regulations 1999 and Water Bylaws
2000 (Scotland).
control valve
temporary
connection
control valve
Fig. 5a
Heating
return
3.6.8 FREQUENT FILLING
Frequent filling or venting of the system may be
indicative of a leak. Care should be taken during
the installation of the appliance to ensure all
aspects of the system are capable of withstanding pressures up to at least 3 bar.
3.7 ELECTRICAL SUPPLY
The appliance is supplied for operation on 230V
@ 50Hz electrical supply; it must be protected
with a 3-amp fuse. The method of connection to
the mains electricity supply must allow for complete isolation from the supply. The preferred
method is by using a double-pole switch with a
contact separation of at least 3mm. The switch
must only supply the appliance and its corresponding controls, i.e. time clock, room thermostat, etc. Alternatively an un-switched shuttered
socket with a fused 3-pin plug both complying
with BS 1363 is acceptable.
flow/return
pipe
Fig. 5
8
double check
valve
supply pipe
3.8 SHOWERS
If the appliance is intended for use with a shower,
the shower must be thermostatically controlled
and be suitable for use with a combination boiler.
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3.9 MOUNTING ON A COMBUSTIBLE SURFACE
If the appliance is to be fitted on a wall of
combustible material, a sheet of fireproof material must protect the wall.
3.10 TIMBER FRAMED BUILDING
If the appliance is to be fitted in a timber framed
building, it should be fitted in accordance with the
Institute of Gas Engineers publication (IGE/UP/
7) ‘Guide for Gas Installations in Timber Frame
Buildings’.
3.11 INHIBITORS
It is recommend that an inhibitor - suitable for use
with copper and aluminium heat exchangers - is
used to protect the boiler and system from the
effects of corrosion and/or electrolytic action.
The inhibitor must be administered in strict accordance with the manufacturers instructions*.
*Water treatment of the complete heating system
- including the boiler - should be carried out in
accordance with BS 7593 and the Domestic
Water Treatment Association’s (DWTA) code of
practice.
Fig. 6a
Fig. 6
9
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SECTION 4 INSTALLATION
4.1 DELIVERY
Due to the weight of the appliance it may be necessary
for two people to lift and attach the appliance to its
mounting. The appliance is contained within a heavyduty cardboard carton. Lay the carton on the floor with
the writing the correct way up.
4.2 CONTENTS
Contained within the carton is:
● the boiler
● the wall bracket
● appliance template
● an accessories pack containing appliance serv-
ice connections and washers
● the instruction pack containing the installation
& servicing instructions, user instructions,
Benchmark logbook, guarantee registration card
and a 3-amp fuse.
4.3 UNPACKING
At the top of the carton pull both sides open - do
not use a knife - unfold the rest of the carton from
around the appliance, carefully remove all protective packaging from the appliance and lay the
accessories etc. to one side. Protective gloves
should be used to lift the appliance, the appliance
back-frame should be used for lifting points.
Horizontal flue terminals and accessories
Part No. Description Min-Max Length
489 Telescopic flue terminal kit 350/500mm
491 Horizontal flue kit for use with 1000 mm
add. bends & extensions
492 0.5m extension 500 mm
493 1.0m extension 1000 mm
494 2.0m extension 2000 mm
495 45º bend (pair) N/A
496 90º bend N/A
499 Wall bracket N/A
Using the template provided, mark and drill a
115mm hole for the passage of the flue pipe. The
hole should be drilled level to ensure any condense fluid that forms will drain back to the boiler.
The fixing holes for the wall-mounting bracket
should now be drilled and plugged, an appropriate type and quantity of fixing should be used to
ensure that the bracket is mounted securely.
Once the bracket has been secured to the wall,
mount the appliance onto the bracket.
Terminal or
extension
4.4 PREPARATION FOR MOUNTING THE APPLIANCE
The appliance should be mounted on a smooth,
vertical, non-combustible surface, which must be
capable of supporting the full weight of the appliance. Care should be exercised when determining the position of the appliance with respect to
hidden obstructions such as pipes, cables, etc.
When the position of the appliance has been
decided - using the template supplied - carefully
mark the position of the wall- mounting bracket
(see fig. 6) and flue-hole (if applicable).
4.5 FITTING THE FLUE
The top flue outlet permits both horizontal and
vertical flue applications to be considered.
4.5.1 CONCENTRIC HORIZONTAL FLUE
(For concentric vertical flue, see section 4.5.2).
The appliance flue outlet elbow can be rotated
through 360º on its vertical axis. In addition the
flue may be extended from the outlet elbow in the
horizontal plane (see 2.9). A reduction must also
be made to the maximum length (see table
below) when additional bends are used.
Reduction for additional bends
Bend Reduction in maximum flue length for each bend
45º bend 0.5 metre
90º bend 1.0 metre
outer
clamp
Boiler
Fig. 7
FITTING THE HORIZONTAL FLUE KIT
Carefully measure the distance from the centre of
the appliance flue outlet to the edge of the finished outside wall (dimension X). Add 65mm to
dimension X to give you dimension Y (see fig 7A).
Measure dimension Y from the terminal end of
the concentric flue pipe and cut off the excess
from the 100mm pipe ensuring any burrs are
removed. Using the cut-off piece of 100mm pipe
as a guide, mark and cut the same length of pipe
from the inner 60mm pipe (the 60mm should
always project past the 100mm pipe by 30mm).
Pass the concentric flue pipe through the previously drilled hole. Fit the flue bend to the boiler
flue outlet and insert the concentric flue pipe into
the flue bend ensuring the correct seal is made.
Using the clamps, gaskets, and screws supplied,
secure the flue bend to the appliance flue spigot
and the flue terminal.
NOTE
Fit the internal (White) trim to the flue assembly
prior to connecting the flue pipe to the bend.
10
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Fig. 7a
an extension or bend can be connected to the
appliance flue outlet if desired (see 4.4.2), however if additional bends are fitted, a reduction
must be made to the maximum flue length (see
table below).
Reduction for bends
Bend Reduction in maximum flue length for each bend
45º bend 0.5 metre
90º bend 1.0 metre
FLUE RESTRICTOR RING (horizontal flue)
To ensure maximum efficiency of the appliance,
it may be necessary to fit one of the supplied
flue restrictor rings to the appliance flue outlet
(see tables below).
85 HE
Total flue length Restrictor required
Less than 1.2 metre 82.5mm diameter (fitted)
Less than 3.0 metres 88mm diameter
Less than 4.5 metres not required
100 HE
Total flue length Restrictor required
Less than 2.0 metres 84mm diameter (fitted)
Less than 4.0 metres not required
4.5.1.1 EXTENDING THE FLUE
Connect the bend - supplied with the terminal kit
- to the top of the boiler using clamp (supplied)
see fig. 7. The additional bends & extensions hav e
push-fit connections, care should be taken to
ensure that the correct seal is made when assembling the flue system. Connect the required
number of flue extensions or bends (up to the
maximum equivalent flue length) to the flue terminal (see fig. 7 & 8).
The hole should be drilled level to ensure that any
condense fluid drains back to the appliance.
NOTE
When cutting an extension to the required length,
you must ensure that the excess is cut from the
plain end of the extension (see fig. 7 & 8). Remove any burrs, and check that all seals are located properly. You must ensure that the entire
flue system is properly supported and connected.
Seal the flue assembly to the wall using cement
or a suitable alternative that will provide satisfactory weatherproofing.
4.5.2 CONCENTRIC VERTICAL FLUE
The vertical flue terminal can be connected directly to the appliance flue outlet. Alternatively,
Vertical flue ter minal and accessories
Part No. Description Min-Max Length
490 Vertical flue terminal
497 Pitched roof flashing plate N/ A
498 Flat roof flashing plate N/A
492 0.5m extension 500 mm
493 1.0m extension 1000 mm
494 2.0m extension 2000 mm
495 45º bend (pair) N/ A
496 90º bend N/A
499 Wall bracket N/A
Using the dimensions given in fig. 9 as a reference, mark and cut a 107mm hole in the ceiling
and/or roof.
Fig. 9
145
FLUE RESTRICTOR RING (vertical flue)
To ensure maximum efficiency of the appliance,
it may be necessary to fit one of the supplied
flue restrictor rings to the appliance flue outlet
(see tables below).
85 HE
Total flue length Restrictor required
Less than 2.0 metre 82.5mm diameter (fitted)
Less than 4.0 metres 88mm diameter
Less than 5.5 metres not required
100 HE
Total flue length Restrictor required
Less than 2.8 metres 84mm diameter (fitted)
Less than 5.0 metres not required
Fig. 8
11
Supplied By www.heating spares.co Tel. 0161 620 6677
Fit the appropriate flashing plate to the roof and
insert the vertical flue terminal through the flashing plate from the outside, ensuring that the collar
on the flue terminal fits over the flashing.
The fixing holes for the wall-mounting bracket
should now be drilled and plugged, an appropriate type and quantity of fixing should be used to
ensure that the bracket is mounted securely.
Once the bracket has been secured to the wall,
mount the appliance onto the bracket.
IMPORTANT
The vertical flue terminal cannot be cut; therefore
it may be necessary to adjust the height of the
appliance to suit or use a suitable extension.
Connect the vertical flue assembly to the boiler flue
spigot using the 60mm & 100mm clips, gaskets &
screws (supplied), ensuring the correct seal is
made. The flue support bracket (supplied with the
vertical flue kit) can now be fitted.
If the vertical flue requires extension/s or additional bend/s, connect the required number of
flue extensions or bends (up to the maximum
equivalent flue length) between the boiler and
vertical flue assembly (see fig. 8).
Ensure that any horizontal sections of the flue
system have a minimum 1º fall back to the boiler
(17mm per 1000mm).
NOTE
When cutting an extension to the required length,
you must ensure that the excess is cut from the
plain end of the extension (see fig. 8). Remove
any burrs, and check that any seals are located
properly. You must ensure that the entire flue
system is properly supported and connected.
4.6 CONNECTING THE GAS AND WATER
The appliance is supplied with an accessory pack
that includes service valves.
The service valves are of the compression type.
The accessory pack contains sealing washers’ etc,
for use with the service valves. When connecting
pipe work to the valves, tighten the compression
end first then insert the sealing washers before
tightening the valve to the appliance.
NOTE
It will be necessary to hold the valve with one
spanner whilst tightening with another
NOTE
Depending on system requirements, it may necessary to increase the size of the flow & return pipe
work after the service valve connections.
4.6.3 COLD WATER INLET (fig. 6 & 10)
The appliance is supplied with a 15mm stopcock,
connect a 15mm pipe to the inlet of the stopcock
and tighten both nuts.
4.6.4 HOT WATER OUTLET (fig. 6 & 10)
The appliance is supplied with a 15mm outlet
connection, connect a 15mm pipe to the outlet
connection and tighten both nuts.
4.6.5 SAFETY VALVE (fig. 6 & 10)
Connect the safety valve pipe to the safety valve
outlet and tighten. The discharge pipe must have
a continuous fall away from the appliance to
outside and allow any water to drain away thereby
eliminating the possibility of freezing. The discharge pipe must terminate in a position where any
water - possibly boiling - discharges safely without
causing damage or injury, but is still visible.
4.6.6 CONDENSE PIPE (fig. 6 & 10)
During normal operation the boiler produces condense which is collected in a trap located in the
lower part of the boiler. A flexible pipe (condense
outlet pipe) is connected to the outlet of the trap.
The flexible pipe must be connected to a plastic
waste pipe only. The plastic waste pipe must have
a minimum of a 3º fall towards the drain. Any
external run of pipe should be insulated to prevent
the risk of freezing.
CONNECTING THE CONDENSATE OUTLET
Gently pull the condense outlet pipe down from its
location inside the boiler until approximately it
protrudes from the underside of the boiler. Connect a suitable plastic (not copper) pipe (no less
than 21mm diameter) to the outlet pipe and ensure
it discharges in accordance with local building
regulations or other rules in force.
condense
4.6.1 GAS (fig. 6 & 10)
The appliance is supplied with a 15mm service
valve, connect a 15mm pipe to the inlet of the
valve and tighten both nuts.
NOTE
It will be necessary to calculate the diameter of
the gas supply pipe to ensure the appliance has
an adequate supply of gas.
4.6.2 FLOW & RETURN (fig. 6 & 10)
The appliance is supplied with 22mm service
valves for the flow and return connections, connect a 22mm pipe to the inlet of each valve and
Fig. 10
tighten both nuts.
12
flow
DHW
outlet
gas
return
DHW
inlet
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