INSTRUCTION MANUAL
INSTALLATION COMMISSIONING & SERVICING
FLOOR STANDING RSF GAS-FIRED CONDENSING COMBINATION
BOILER
GREENSTAR
HIGHFLOW 440CDi & 550CDi
FOR SEALED CENTRAL HEATING SYSTEMS AND MAINS FED DOMESTIC HOT WATER
THE APPLIANCE IS FOR USE WITH
NATURAL GAS OR L.P.G. (Cat II 2H3P TYPE C13, C33 & C93)
NATURAL GAS:
GREENSTAR HIGHFLOW 440CDi GC NUMBER 47-406-24
GREENSTAR HIGHFLOW 550CDi GC NUMBER 47-406-25
LIQUID PETROLEUM GAS:
GREENSTAR HIGHFLOW 440CDi GC NUMBER 47-406-26
GREENSTAR HIGHFLOW 550CDi GC NUMBER 47-406-27
UK/IE
8 716 115 219b (09.2008)
CONTACT INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS
WORCESTER, BOSCH GROUP:
MAIN RECEPTION: 01905 754624
MAIN FAX: 01905 754619
TECHNICAL: 08705 266241
SERVICE: 08457 256206
SPARES: 01905 752571
LITERATURE: 01905 752556
TRAINING: 01905 752526
SALES: 01905 752640
WEBSITE: worcester-bosch.co.uk
WATER TREATMENT:
FERNOX 01799 550811
fernox.com
SENTINEL 0800 389 4670
sentinel-solutions.net
FLUE TERMINAL GUARDS:
TOWER FLUE COMPONENTS
VALE RISE, TONBRIDGE, TN9 1TB
TEL: 01732 351680
tfc-group.co.uk
IMPORTANT HANDLING INSTRUCTIONS:
It is advised that at least two people are
involved in the transfer of the packaged
appliance from the van to the point of
installation.
A suitable truck should be used.
The boiler is secured to a wooden board with
screws. It is advised that no attempt should
be made to move the packaged appliance
without the use of a suitable truck.
Before removing the carton it is advised that
the top flaps are opened and the ancillary
items removed and set to one side.
The carton can now be lifted off the boiler.
Remove the plastic bag protecting the boiler
surfaces and place safely away from the
working area.
Remove the boiler (complete with board) from
the pallet before removing the securing screws.
The boiler is mounted on small wheels and
can now be slid off the board and guided into
the installation position.
Care should be taken not to damage any
panels.
Two people are required to move the appliance
from the board into the installation position.
GENERAL HANDLING GUIDELINES:
• Lift only a manageable weight, or ask for help.
• When lifting, bend the knees, and keep the
back straight and feet apart.
• Do not lift and twist at the same time.
• Lift and carry items close to the body
• Wear protective clothing and gloves to
protect from any sharp edges
Store the appliance in a dry area prior to
installation.
THIS BOILER IS NOT SUITABLE FOR ROOF
SPACE INSTALLATION.
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
THESE INSTRUCTIONS ARE APPLICABLE TO THE PRODUCT MODEL(S) STATED ON
THE FRONT COVER OF THIS MANUAL ONLY AND MUST NOT BE USED WITH ANY
OTHER MAKE OR MODEL OF APPLIANCE.
THE INSTRUCTIONS APPLY IN THE UK/IE ONLY AND MUST BE FOLLOWED EXCEPT
FOR ANY STATUTORY OBLIGATION.
THIS APPLIANCE MUST BE INSTALLED BY A COMPETENT REGISTERED ENGINEER,
SUCH AS A BRITISH GAS OR OTHER CORGI REGISTERED PERSONNEL.
IF YOU ARE IN ANY DOUBT CONTACT THE WORCESTER TECHNICAL SUPPORT
HELPLINE.
DISTANCE LEARNING AND TRAINING COURSES ARE AVAILABLE FROM WORCESTER,
PART OF THE BOSCH GROUP.
PLEASE LEAVE THESE INSTRUCTIONS, THE USER GUIDE AND THE COMPLETED
BENCHMARK LOG BOOK (AT THE BACK OF THIS MANUAL) OR A CERTIFICATE
CONFIRMING COMPLIANCE WITH IS 813 (EIRE ONLY) WITH THE USER OR AT
THE GAS METER AFTER INSTALLATION OR SERVICING.
COMMERCIAL INSTALLATION:
IF INSTALLING A GROUP OF APPLIANCES TOGETHER, ON COMMERCIAL PREMISES,
THAT TOTALS MORE THAN 70KW, THEN THE APPLIANCES MUST BE INSTALLED IN
ACCORDANCE WITH THE REQUIREMENTS OF IGE/UP/10 THEREFORE A COMMERCIAL
GAS QUALIFICATION WILL BE REQUIRED.
ABBREVIATIONS:
Ø Diameter
NG Natural Gas
LPG Liquid Petroleum Gas
CH Central Heating
DHW Domestic Hot Water
TRV Thermostatic Radiator Valve
IP Ingress Protection
RS Room sealed flue
N/A Not allowed
SEDBUK Seasonal Efficiency for Domestic Boilers in the United Kingdom
SYMBOLS USED IN THIS MANUAL:
Domestic hot water
Central heating
Room thermostat
Frost thermostat
Wait time period
Programmer/timer OFF
Programmer ON CH only
Programmer ON DHW only
Programmer ON CH and DHW
Cold water main supply
Electricity supply
Fuel supply
CONTACT INFORMATION
INSTALLATION & SERVICING INSTRUCTIONS
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
CONTENTS
SAFETY & REGULATIONS
SAFETY PRECAUTIONS 2
INSTALLATION REGULATIONS 2
APPLIANCE INFORMATION
GENERAL INFORMATION 3
TECHNICAL DATA 4
LAYOUT & COMPONENTS 5
PRE-INSTALLATION
CLEANING PRIMARY SYSTEMS 6
MAINS SUPPLIES 7
WATER SYSTEMS & PIPEWORK 9
CONDENSATE PIPEWORK 11
PRESSURE RELIEF PIPEWORK 12
BOILER LOCATION & CLEARANCES 13
MOUNTING FRAME CONNECTIONS 14
TERMINAL OUTLET POSITIONS 17
ROOM SEALED FLUE OPTIONS 18
INSTALLATION
UNPACKING THE BOILER 19
MOUNTING FRAME FIXING / FLUE OPENING 20
MOUNTING FRAME CONNECTIONS 21
FLUE LENGTHS/FLUE MEASURING & CUTTING 22
FLUE MEASURING & CUTTING 23
FLUE INSTALLATION 25
STANDARD FLUE INSTALLATION 26
EXTENDED FLUE INSTALLATION 27
FLUE TERMINAL PLUME MANAGEMENT 28
CONDENSATE, GAS & WATER CONNECTIONS 29
PRESSURE RELIEF VALVE OUTLET 30
ELECTRICAL 31
SAFETY &
REGULATIONS
APPLIANCE
INFORMATION
PRE-
INSTALLATION
INSTALLATIONCOMMISSIONING
COMMISSIONING
PRE-COMMISSIONING CHECKS 32
FILLING THE SYSTEM 33
WATER TREATMENT 34
STARTING THE APPLIANCE 35
FINISHING COMMISSIONING 36
SERVICING & SPARES
INSPECTION AND SERVICE 37
REPLACEMENT OF PARTS 41
SETTING THE GAS/AIR RATIO 46
SHORT PARTS LIST 47
CONVERSION KITS
L.P.G. CONVERSION 48
FAULT FINDING & DIAGRAMS
ELECTRICAL WIRING DIAGRAM 49
CENTRAL HEATING FUNCTION 50
DHW FUNCTION 51
FAULT FINDING 52
BENCHMARK LOG BOOK AT REAR OF MANUAL
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
CONTENTS
& SPARES
SERVICING
KITS
CONVERSION
& DIAGRAMS
FAULT FINDING
1
SAFETY PRECAUTIONS INSTALLATION REGULATIONS
IF YOU SMELL GAS:
SAFETY &
REGULATIONS
DON'T SMOKE OR STRIKE MATCHES.
DON'T TURN ELECTRICAL SWITCHES ON
DO PUT OUT NAKED FLAMES.
DO OPEN DOORS AND WINDOWS.
DO KEEP PEOPLE AWAY FROM THE AREA AFFECTED.
DO TURN OFF THE CONTROL VALVE AT THE METER.
DO CALL YOUR GAS COMPANY.
BOILER OPERATION:
This boiler must only be operated by a responsible adult who has been instructed
in, understands and is aware of the boiler’s operating conditions and effects.
BENCHMARK:
A Benchmark Log Book is provided, at the back of this manual, for the installer to
complete including their CORGI registration number to confirm that the boiler has
been installed, commissioned and serviced according to the manufacturer’s instructions.
IMPORTANT: The completed Benchmark Log Book will be required in the event of any
warranty work and may be required by the local Building Control Inspector.
HEALTH & SAFETY:
The appliance contains no asbestos and no substances have been used in the
construction process that contravene the COSHH Regulations (Control of Substances
Hazardous to Health Regulations 1988). Where applicable, the CE mark indicates
compliance with relative EU Directives.
COMBUSTIBLE AND CORROSIVE MATERIALS:
Do not store or use any combustible materials (paper, thinners, paints etc.) inside
or within the vicinity of the appliance.
The combustion air must be kept clear of chemically aggressive substances, which
can corrode the appliance and invalidate any warranty.
OR OFF.
Failure to install appliances correctly could
lead to prosecution.
This appliance must be installed by a
competent registered engineer, such as British
Gas or other CORGI registered personnel, in
accordance with, and comply to, the current:
Gas Safety (Installation & Use) Regulations
1998, IEE Regulations, Building Regulations,
Building Standards (Scotland)
(Consolidation), Building Regulations
(Northern Ireland), local water by-laws, Health
& Safety Document 635 (The Electricity at
Work Regulations 1989), IS 813 (Eire) and
any other local requirements.
The relevant Standards should be followed,
including:
BS7074:1 : Code of practice for domestic
heating and hot water supply
BS6891 : Installation of low pressure gas
pipework up to 32mm (R1
BS EN:12828 : Central heating for domestic
premises
BS5440:1 : Flues and ventilation for gas
appliances of rated heating not exceeding
70kW (net) : Flues
BS5440:2 : Flues and ventilation for gas
appliances of rated heating not exceeding
70kW (net) : Air Supply
BS7593 : Treatment of water in domestic hot
water central heating systems
BS6798 : Installation of gas fired boilers of
rated input up to 70kW (net)
Where no specific instruction is given,
reference should be made to the relevant
codes of Practice.
1/4)
FITTING & MODIFICATIONS:
Fitting the appliance and any controls to the appliance may only be carried out by
a competent engineer in accordance with these instructions and the relevant Installation
Regulations.
Flue systems must not be modified in any way other than as described in the fitting
instructions.
Any misuse or unauthorised modifications to the appliance, flue or associated
components and systems could invalidate the warranty. The manufacturer accepts
no liability arising from any such actions, excluding statutory rights.
SERVICING:
Advise the user to have the system regularly serviced by a competent, qualified
engineer (such as British Gas or other CORGI registered personnel) using approved
spares, to help maintain the economy, safety and reliability of the appliance.
IMPORTANT - The service engineer must complete the Service Record in the
Benchmark Log Book after each service.
2
SAFETY PRECAUTIONS &
L.P.G. Installation:
An appliance using L.P.G. must not be installed
in a room or internal space below ground
level unless one side of the building is open
to the ground.
Timber framed buildings:
Where the boiler is to be fitted to a timber
framed building the guidelines laid down in
BS5440: Part 1 and IGE "Gas Installations in
Timber Frame Buildings” should be adhered
to.
IMPORTANT:
Artificially softened water must not be used
to fill the central heating system.
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
INSTALLATION REGULATIONS
GENERAL INFORMATION
STANDARD PACKAGE:
A - Floor standing gas fired combination
boiler for central heating and domestic
hot water.
B - Mounting frame complete with pre-
plumbing manifold assembly.
C - Literature pack.
A
D - Condensate waste pipe & non-return valve
SPECIFICATIONS:
Pre-wired and pre-plumbed.
Galvanised steel inner frame.
Bosch Heatronic control system.
850mm
600mm
600mm
B
Automatic ignition.
Direct burner ignition electrodes.
Built-in frost thermostat.
Built-in fault finding diagnostics.
Modulating automatic gas valve.
Combustion air fan with speed regulator.
CH temperature sensor & control.
DHW flow sensor & temperature control.
Integral water circulating pump with antiseizure protection.
Sealed primary system & pressure gauge
display.
Pressure relief valve.
Flue gas temperature limiter.
Plate-type DHW heat exchanger.
Condensate trap & pump.
APPLIANCE
INFORMATION
D
C
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
GENERAL INFORMATION
3
DESCRIPTION UNITS Natural Gas L.P.G
Central Heating
Max. rated heat output net 40/30°C kW 31.2 32.8 31.2 32.8
Max. rated heat output net 50/30°C kW 30.9 32.5 30.9 32.5
Max. rated heat output net 80/60°C kW 29.2 30.6 29.2 30.6
Max. rated heat input net kW 29.6 31 29.6 31
Min. rated heat output net 40/30°C kW 8.4 11 11.6 13.4
APPLIANCE
Min. rated heat output net 50/30°C kW 8.3 10.9 11.4 13.2
INFORMATION
Min. rated heat output net 80/60°C kW 7.4 9.7 10.5 12.1
Min. rated heat input net kW 7.6 10 10.8 12.5
Max. flow temperature °C88888888
Max. permissible operating pressure bar 2.5 2.5 2.5 2.5
Domestic Hot Water
Max. rated heat input net kW 29.6 41.5 29.5 41.5
Max. rated heat output kW 29.5 41.1 29.2 41.1
Minimum flow rate to start l/min 2.3 2.8 2.3 2.8
Minimum pressure for max flow rate 20 l/min (±15%) bar 1.5 - 1.5 -
Minimum pressure for max flow rate 25 l/min (±15%) bar - 1.7 - 1.7
Gas flow rate - Max. 10 minutes from lighting
Natural Gas G20 m
Propane Gas (LPG) kg/h - 2.3 3.2
Gas supply pressure
Natural Gas G20 mb 20 20 -
LPG (Propane) Gas G31 mb - 37 37
Flue
Flue Gas Temp. 80/60°C, rated min. load °C 67/55 67/55 67/55 67/55
Flue Gas Temp. 40/30°C, rated min. load °C 43/32 43/32 43/32 43/32
CO
CO
NO
Condensate
Max. condensation rate l/h 2.7 3.7 2.7 3.7
pH value, approx. 4.8 4.8 4.8 4.8
Electrical
Electrical power supply voltage AC...V 230 230 230 230
Frequency Hz 50 50 50 50
Max. power consumption W 164 206 164 206
Expansion Vessel
Charge Pressure bar 0.75 0.75 0.75 0.75
Total Capacity Itr 12 12 12 12
General Data
SEDBUK (Band A) % 90.8 90.8 92.2 92.2
Appliance protection rating IP x4D x4D x4D x4D
Appliance protection rating (with mechanical timer fitted into fascia) IP 20 20 20 20
Permissable ambient temperatures °C 0 - 50 0 - 50 0 - 50 0 -50
Nominal capacity of appliance Itr 51 51 51 51
Noise output level (at maximum CH output) dB(A) 37 37 37 37
Weight (excluding packaging) kg 112 112 112 112
TECHNICAL DATA
440CDi 550CDi 440CDi 550CDi
2
/h 3.1 4.4 -
level at max. rated heat output % 9.4 9.4 10.8 10.8
2
level at min. rated heat output % 8.6 9.0 10.4 10.4
2
- classification class 5 5 5 5
x
4
TECHNICAL DATA
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
10
LAYOUT & COMPONENTS
The diagram opposite shows the controls in
the servicing position and excludes the outer
case, inner covers and wiring.
1 CONTROL PANEL
F
E
D
C
B
A
1
2
3
4
5
17
11
41
42
20
16
19
22
21
23
43
24
25
26
1
15
18
40
14
39
27
6
13
7
8
9
12
38
37
36
35
34
33
32
31
30
29
2 MASTER SWITCH FOR ON/OFF
3 BURNER ON INDICATOR LIGHT (GREEN)
4 SERVICE BUTTON
5 CENTRAL HEATING BOOST BUTTON
6 DISPLAY
7 RESET BUTTON
8 ECO BUTTON
9 NOT USED
10 CH TEMPERATURE CONTROL
11 MAINS ON/OFF INDICATOR & FAULT
DIAGNOSTIC LIGHT
12 DHW TEMPERATURE CONTROL
13 SYSTEM PRESSURE GAUGE
14 POSITION FOR OPTIONAL PROGRAMMER
15 TANK TEMPERATURE SENSOR
16 TANK OVERHEAT THERMOSTAT
17 DHW HEAT EXCHANGER
18 FILLING LOOP ISOLATION VALVE
19 WATER FLOW SENSOR TURBINE
20 BOILER/TANK DRAIN & CONNECTION
POINT FOR FILLING LOOP
21 DHW FLOW SENSOR
22 CH FLOW ISOLATION VALVE
23 DHW OUTLET
24 GAS ISOLATION VALVE
25 MAINS WATER INLET ISOLATION VALVE
26 CH RETURN ISOLATION VALVE
27 RUNNER WHEEL ON MOUNTING FRAME
28 OPTIONAL FILLING LINK WITH PRESSURE
GAUGE: PART NO: 7 716 192 599
29 CIRCULATING PUMP
30 CONDENSATE PUMP ASSEMBLY
31 GAS VALVE
32 EXPANSION VESSEL
33 AIR/GAS ADJUSTMENT SCREW (SEALED)
34 HEAT CELL
35
36 GAS BURNER/SPARK ELECTRODES
37 COMBUSTION AIR MODULATING FAN
38 FLUE BLANKING PLATES
39 CASING SUPPORT STRUT
40 CASE ‘KNOCK-OUT’ PANEL-FLUE
41 AUTO AIR VENT
42 SYSTEM PRESSURE RELIEF VALVE
43 HEAT STORE
100mmØ HORIZONTAL FLUE
COMPONENTS (Kit Part No. 7 716 191 155)
A - 93° ELBOW
B - ADAPTOR
C - CONNECTOR
D - INNER WALL FLUE COLLAR
E - TELESCOPIC TERMINAL ASSEMBLY
F - OUTER WALL FLUE COLLAR
FLUE KITS:
Vertical 100mmØ Part No. 7 716 191 156
Vertical 125mmØ Part No. 7 716 191 158
Horizontal 125mmØ Part No. 7 716 191 157
APPLIANCE
INFORMATION
28
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
LAYOUT & COMPONENTS
5
CLEANING PRIMARY SYSTEMS
PRE-
INSTALLATION
IMPORTANT: All the following pre-installation sections must be read and
requirements met before starting boiler or flue installation.
CAUTION: ISOLATE THE MAINS SUPPLIE S BEFORE STARTING ANY WORK
AND OBSERVE ALL RELEVANT SAFETY PRECAUTIONS.
IMPORTANT:
Debris from the system can damage the
boiler and reduce efficiency. Failure to
comply with the guidelines for the use
of water treatment with the appliance
will invalidate the appliance warranty.
BEFORE CLEANING THE SYSTEM:
ENSURE THE SYSTEM AND PIPEWORK ARE
IN GOOD WORKING ORDER.
USE THE EXISTING BOILER/CIRCULATING
PUMP WHERE POSSIBLE OR USE A POWER
FLUSHING MACHINE TO AID THE CLEANSING
PROCEDURE BEFORE INSTALLING A NEW
BOILER.
CLEANING THE PRIMARY SYSTEM:
Fill the system with cold mains water to
the recommended pressure and check for
leaks.
Open all drain cocks and drain the system.
Close drain cocks and add a suitable
flushing agent at the correct strength for
the system condition in accordance with
the manufacturer's instructions.
Circulate the flushing agent before the
boiler is fired up.
Run the boiler and system at normal
operating temperature in accordance with
the manufacturer's instructions.
Drain and thoroughly flush the system to
remove the flushing agent and any debris.
6
CLEANING PRIMARY SYSTEMS
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
MAINS WATER EXPANSION VESSEL:
A - Mini expansion vessel, part No. 7 716 192 105
B - Water Main supply pipe
C - Non-return valve
D - Boiler
D
A
B
C
MAINS SUPPLIES
ELECTRICAL SUPPLY:
• Supply: 230V - 50Hz.
• Cable: PVC insulated 0.75mm
0.2mm) temperature rated to 90°C.
• External 3A fuse to BS1362.
• The appliance must be earthed.
• It must be possible to isolate the appliance
from the electric supply with at least a
3mm contact separation in both poles
supplying the appliance.
• Wiring between the appliance and the
electrical supply must comply with IEE
wiring regulations and any local regulations
which may apply for fixed wiring to a
stationary appliance.
• Any system connected to the boiler must
not have a separate electricity supply.
WATER SUPPLY:
• Connections to the water supply must not
be made without the authority of the local
water company.
• The appliance cold water supply should
be the first connection off the water main
where possible.
Water Mains Pressure:
• Minimum dynamic mains water pressure
1.2 bar for maximum performance.
• Maximum mains fed water pressure 10 bar.
If necessary, fit a pressure reducing valve.
IMPORTANT: Non-return, back flow
prevention devices (including those
associated with water meters) fitted to
the mains water supply can cause a
pressure build up which could damage
the boiler and other household
appliances.
• Where the water main supply has a non-
return, back flow prevention valve fitted,
a mini expansion vessel (A) should be
connected to the mains water inlet pipe
(B) between the non-return valve (C) and
the boiler (D) as shown opposite.
Use in hard water areas:
Normally there is no need for water treatment
to prevent scale formation as the maximum
temperature of the heat exchanger is limited
by the electronic control circuit.
In areas where the temporary water hardness
exceeds 200ppm, consideration may need to
be given to the fitting of a scale prevention
device. In such circumstances, the advice of
the local water authority should be sought.
2
(24 x
PRE-
INSTALLATION
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
MAINS SUPPLIES
7
PRE-
INSTALLATION
MAINS SUPPLIES
GAS SUPPLY:
• Boilers using NG must be connected to a
governed meter.
• LPG boilers must be connected to a
regulator.
• Installation and connection of the gas
supply to the boiler must be in accordance
with BS6891.
• Under no circumstances should the
diameter of the gas supply pipe be less
than that of the appliance inlet connection.
• The meter or regulator and pipework to
the boiler must be checked, preferably by
the gas supplier to ensure it is in good
working order and can meet the gas flow
and pressure requirements in addition to
the demand from any other appliance being
served.
8
MAINS SUPPLIES
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)8 716 115 219b (09.2008)
TYPICAL SEALED SYSTEM:
A
B
P
C
WATER SYSTEMS & PIPEWORK
PRIMARY SYSTEM PLASTIC PIPEWORK:
• Any plastic pipework must have a polymeric
barrier with 600mm (minimum) length of
copper connected to the boiler.
• Plastic pipework used for underfloor
heating must be correctly controlled with
a thermostatic blending valve limiting the
temperature of the circuits to approx. 50°C.
The pipework from the boiler to the
blending valve must be in copper.
PRIMARY
SYSTEM/CONNECTIONS/VALVES:
• Do not use galvanised pipes or radiators.
• All system connections, taps and mixing
valves must be capable of sustaining a
pressure of 3 bar.
• Radiator valves should conform to
BS2767:10.
• All other valves should conform to BS1010.
• On new installations TRV’s must be used
on all radiators except the radiator where
the room thermostat is sited, this must be
fitted with lockshield valves and left open.
All installations should have TRV's fitted
to radiators within the sleeping
accommodation.
• Drain cocks are required at all the lowest
points on the system.
• Air vents are required at all high points on
the system.
R R
T
R R
T
D
T
L
T
L
L
L
SEALED PRIMARY SYSTEM:
• Where the system volume is more than
100 litres or exceeds 2.5bar at maximum
heating temperature an extra expansion
vessel (B) must be fitted as close as
possible to the appliance in the central
heating return.
• Pressurise the extra expansion vessel (B)
to the same figure as the expansion vessel
built into the appliance - REFER TO
TECHNICAL DATA TABLE.
D
PRE-
INSTALLATION
A - Appliance expansion vessel
B - Extra expansion vessel
C - Automatic bypass valve
D - Drain cock
L - Lockshield valve
P - Pressure relief discharge
R - Radiators
T - TRV
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
WATER SYSTEMS & PIPEWORK
9
PRE-
Heating return
Stop
cock
Hose
return
Temporary
hose
Non
return
valve
return
valve
Test cock
Non
Water main
supply
Stop
cock
WATER SYSTEMS & PIPEWORK
FILLING PRIMARY SYSTEMS:
• The CH sealed system must be filled using
a WRAS approved filling loop or comply
with the diagram opposite for system fill.
• The filling point must be at low level and
must never be a permanent direct fixing
to the mains water supply.
SHOWERS/BIDETS:
• If a shower head can be immersed in water
or comes closer than 25mm from the top
edge of a bath or shower tray spill over
level then an anti-siphon device must be
fitted to the shower hose.
• Bidets with direct hot & cold mains water
can be used (with the approval of the local
water authority) and must be the over rim
flushing type with shrouded outlets to
prevent the fitting of hand held sprays.
INSTALLATION
DOMESTIC HOT WATER:
• Taps and mixing valves must be capable
of sustaining a pressure up to 10 bar.
• Hot water temperature and flow rate are
affected by the size and insulation of
pipework making up the distribution system
and are controlled by the hot water tap
and the water main inlet pressure. A mixing
valve can be fitted if a more permanent
setting is required.
• If using more than one outlet at once
causes water flow starvation, fit flow
balancing valves or Ball-O-Fix valves to the
appropriate outlets.
10
WATER SYSTEMS & PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
CONDENSATE PIPEWORK
Condensing
Boiler
-
22mmØ
plastic pipe
Condensing
Boiler
500mm min.
Visible air break
at plug hole
Sink with
integral
75 mm
min.
75mm sink
waste trap
22mmØ
Invert
overflow
Insulation or
increase pipe size
Condensate drainage pipe can be
run above or below ground
100mm
22mmØ condensate
drainage pipe, max external
length 3 metres
Insulation or
increase pipe size
Open end of
condensate drainage
pipe directly into gully
below grating but
above water level
Soil & vent stack
minimum
450mm
and up to
3 storeys
IMPORTANT:
• Ensure there are no
blockages in the pipe run
• Care should be taken when
siting a soak-away to avoid
obstructing existing services
• Condensate waste must not
be terminated into a septic
tank or cesspit
CONDENSATE PIPEWORK:
• The condensate pipe must be a minimum of
22mm Ø plastic pipe.
• The condensate pipework must fall at
least 50 mm per metre towards the outlet
and should take the shortest practicable
route.
• The pipework must follow one of the options
shown opposite or discharge directly into a
vent stack min. 450mm above pipe invert or
into a gully below ground but above the water
level.
• Wherever possible the condensate
discharge pipe work should be routed and
terminated internally. Should this not be
possible, and the only available route is
external, the following conditions should be
observed:
External pipe work
- Pipe work length should be kept to a
minimum and the route as vertical as
possible.
- Where pipe work is subjected to
extreme cold or wind chill, a weather
proof insulation should be used.
Alternatively the condensate pipework
could be increased to a minimum
diameter of 32mm without the
requirement to insulate.he pipe run
PRE-
INSTALLATION
Diameter 100mm
min. plastic tube
Bottom of
tube sealed
Limestone
chippings
22 mm Ø plastic condensate
drainage pipe running
through the external wall
Condensing
Boiler
Hole depth
400mm min.
by 300 Ø
Insulation or
increase pipe size
43 mm 90°
M & F bend
25mm
Drainage holes
External rain water
pipe into foul water
External
air break
Air gap
68 mm Ø PVC-u
strap on fitting
Condensate soakaway
The condensate drainage pipe may be run
above or below the ground to the soakaway.
The example shown opposite runs above
ground level.
The soakaway must use a 100mm diameter
plastic tube with two rows of three 12 mm
holes on 25 mm centres and 50 mm from
the bottom of the tube. The holes must face
away from the house.
The tube must be surrounded by at least
100 mm of limestone chippings to a depth
of 400mm.
Fitting an external air break
Use the situation opposite when a rain water
down pipe is used to dispose of condensate
and the down pipe goes directly into an
existing sewer that carries both rainwater
and foul water.
An air break must be installed in the
32/43mm
pipework, between the boiler
condensate outlet and the drainpipe, outside
the property, to avoid flooding during
adverse weather conditions.
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
CONDENSATE
11
PIPEWORK
PRESSURE RELIEF PIPEWORK
IMPORTANT: Debris from the system
can damage the boiler and reduce
efficiency. Failure to comply with the
guidelines for the use of water treatment
with the appliance will invalidate the
appliance warranty.
• The pressure relief drain pipe (A) should
be at least 15mm diameter copper pipe
and run downwards away from the boiler
and discharge away from any electrics or
other hazard, preferably to an external
drain or soakaway.
PRE-
INSTALLATION
A
B
A
• Pipe (A) should be finished with a partial
bend, near the outlet to face the external
wall(as shown) to help prevent freezing.
A - Drain pipe.
B - Outside wall.
12
PRESSURE RELIEF PIPEWORK
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
1: INSTALLATION CLEARANCES
1200mm
610mm
600mm
5mm
1450mm
600mm
3: UNVENTED
COMPARTMENT CLEARANCES
800mm
800mm
50mm
5mm
2: SERVICE / VENTED
CUPBOARD CLEARANCES
1200mm
5mm
865mm
600mm
250mm
*
15mm
610mm
5mm
BOILER LOCATION &
CLEARANCES
• This boiler is only suitable for installing
internally within a property at a suitable
location onto a fixed rigid non-combustible
surface at least the same size as the boiler
and capable of supporting the boiler weight.
• The boiler is not suitable for external installation
unless a suitable enclosure is provided.
• THIS BOILER IS NOT SUITABLE FOR ROOF
SPACE INSTALLATION.
COMMERCIAL INSTALLATION:
• I f installing more than one appliance in a
modular or cascade arrangement in a
commercial premises, that total more than
70kW, then additional ventilation is needed to
comply with the Dangerous Substances and
Explosive Atmospheres Regulations (DSEAR).
Compartments:
Follow the requirements of BS6798 and
BS5440 Part 2 and note:
• Minimum clearances must be maintained.
• An access door is required to install, service
and maintain the boiler and any ancillary
equipment.
• If fitting the boiler into an airing cupboard
use a non-combustible perforated material
(maximum hole sizes of 13mm) to separate
the boiler from the airing space.
1: INSTALLATION CLEARANCES:
Diagram '1' shows the minimum space
required to install the boiler only.
PRE-
INSTALLATION
100mm**
900mm
200mm*
100mm**
2: SERVICE CLEARANCES:
Diagram '2' opposite shows the minimum
space required to service the boiler only.
25mm to an removable door.
3: UNVENTED COMPARTMENT
CLEARANCES:
Diagram '3' shows the minimum space
required to install and service the boiler inside
an unvented compartment.
Space required for unvented areas with a
*
removable door or panel.
This space can be reduced to 50mm for one
**
side only as long as both the side clearances
add up to the total of both the side
measurements shown or more.
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
BOILER LOCATION & CLEARANCES
13
PRE-
INSTALLATION
5: VENTING
COMPARTMENTS
B
D
C
625mm
25mm
100mm
1050mm
4: AIRING CUPBOARD
CLEARANCES
200mm
25mm
800mm
100mm
BOILER LOCATION &
CLEARANCES
4: AIRING CUPBOARD CLEARANCES:
Diagram 'd' opposite shows the minimum
space required to install and service the boiler
within an airing cupboard.
5: VENTING COMPARTMENTS:
If the clearances are less than those stated
for options '3' & '4' (above) then ventilation
must be provided as described in BS 5440.
A minimum of 2 air vents (C) of equal size must
be fitted, one at low level and another at high
level on the same wall using the same air for
circulation.
Minimum free area required for venting:
For area directly from outside:
440CDi 155cm
550CDi 220cm
For air from internal space/room:
440CDi 310cm
550CDi 440cm
2
per vent.
2
per vent.
2
per vent.
2
per vent.
2250mm
600mm
2
2250m
600mm
750mm
1
m
2
1
2
600mm
1
1
2
2250mm
750mm
2250mm
6: BATHROOMS:
IMPORTANT:
Any switch or appliance control using mains
electricity must not be within reach of a
person using the bath or shower.
Electrical switches, fused spurs and socket
outlets must not be situated in the bathroom.
A boiler fitted with a non-mechanical timer or
with no timer can be installed in zone 2 or
outside the shaded area.
A boiler with a mechanical timer or RF
mechanical timer with a room thermostat
must only installed outside the shaded area.
Additional RCD (Residual Current Device)
protection may be required.
Refer to the latest IEE wiring regulations.
14
600mm radius
BOILER LOCATION & CLEARANCES
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
MOUNTING FRAME
CONNECTIONS
CONNECTIONS:
Water: 22mm compression fittings
Gas: 22mm compression fitting.
PRE-PLUMBING:
• With the mounting frame (A) installed,
pipework can be connected to the valves
on the plumbing manifold.
• The system can be filled (without the
boiler being connected) using an optional
charging link assembly (B).
• The valves can be closed enabling the
DHW and CH systems to be tested.
• The boiler can be installed at a later date.
RUNNING PIPES BEHIND THE BOILER:
• The frame should sit against the wall (not
the skirting board) with enough room for
the pipework.
• Do not cross a pipe over another.
• The area around a rear flue outlet must
be avoided.
PRE-
INSTALLATION
C
B (Optional)
A
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
MOUNTING FRAME CONNECTIONS
15
I
• The flue must be fitted and terminated in accordance
with the recommendations of BS5440 : Part 1.
• The flue must not cause an obstruction.
• Discharge and any noise from the flue outlet must not
cause a nuisance.
• Flue gases have a tendency to plume and in certain
weather conditions a white plume of condensation
will be discharged from the flue outlet. Where this
could be a nuisance, for example, near security lighting,
an alternate position should be found.
• The air inlet/outlet duct and the terminal of the boiler
must not be closer than 25mm to any combustible
material.
Detailed recommendations on
protection of combustible materials are
given in BS 5440: Part 1
• A protective terminal guard must be fitted if the
terminal is 2m or less above a surface to which people
have access.
The guard must be spaced equally (minimum 50 mm)
PRE-
around the flue and fixed to the wall with plated
screws. See Contact Information (inside front cover).
NOTE: All measurements are the minimum
INSTALLATION
clearances required.
Terminals must be positioned so to
avoid combustion products entering
the building.
500mm clearance to
any vertical structure
on a roof, 600mm to
another flue or 1500mm
to an open flue.
500mm
300mm
VELUX
600mm
600mm distance to a boundary,
unless it will cause a nuisance.
BS 5440: Part 1 recommends
that care is taken when siting
terminals in relation to boundaries
Deduct one metre off the total flue length for every 45° bend used
Deduct two metres off the total flue length for every 90° bend used
The flue turret has a built-in angle of 3° to
ensure that the condensate flows back to
the boiler for safe disposal via the
condensate waste pipe.
All horizontal flue sections must rise by 3°
or at least 52mm for each metre away from the
boiler to ensure condensate flows back
into the boiler.
Boundary
1000mm
52mm fall 104mm fall
600mm minimum
clearance from
a skylight to a
vertical flue
1000mm
500mm
200mm
200mm below eaves
and 75mm below
gutters, pipes and drains
600mm
500mm
500mm
Vertical flue clearance 500mm
to non-combustible building
material, and 1,500mm clearance
to combustible building material
DRAINP
25mm
16
TERMINAL OUTLET POSITIONS
INSTALLATION & SERVICING INSTRUCTIONS
8 716 115 219b (09.2008)
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