Worcester Bosch Highflow 3.5 RSF Installation And Servicing Instructions

....--

~

~ORCESTER--.

Highflow

ROOM

FLOOR STANDING COMBINATION BOILER FOR CENTRAL

HEATING

SEALED

AND

MAINS

FANNED

FED

3.5

FLUE

DOMESTIC

RSF

MODEL

HOT

WATER

INSTALLATION AND

SERVICING

INSTRUCTIONS

...__

THESE

_____

IMPORTANT:

INSTRUCTIONS

THIS

THESE

:::.

GC

NUMBER

BOILER OUTPUT

To

Maximum

Minimum

Maximum

APPLIANCE

INSTRUCTIONS

ARE

TO

~

23.4

To

Central Heating

8.8

23.4

IS

BE

LEFT

.rwoRCESTER

41

311

Hot Water

kw

(80,000

kW (30,000

kW (80,000

FOR

USE APPLY WITH

Bosch

40

Btu/h)

WITH

IN

THE

USER

Group

NATURAL

UK

ONLY

OR

AT

_____

GAS

THE

ONLY

GAS

METER

...

CONTENTS

INSTALLATION

Section

Section Section

Section

Section Section

Section

Section Section Section

1

2

3

4

5

6

7 8

9

9.1

9.2

9.3

10

11

12

13

14

15

16

17

18 19

20

REGULATIONS

General Siting Removal System Air Terminal Air Connection Installing Rear Vertical

Pre-plumbing Completion Sealed Open Mains Electrical Commissioning System Users Routine Replacement Short Fault

Information

the

Considerations

Supply -Horizontal Supply -Vertical

Horizontal

Flue

Primary

Vent

Feed

Guidance

Instructions

Cleaning

Parts

Finding

AND

TECHNICAL

Appliance

of

Cabinet

Position -Horizontal

of

the

Systems

of

Primary

Domestic

List

Flue

Primary

Appliance -General

Flue

Outlet

of

the

Appliance

the

Installation

System -Open

System ~ Mains

the

Appliance

and

of

Parts

Chart

INSTALLATION REGULATIONS

The

installation

Use)

Regulations, regulations the

following

BS

5440:2:1989 and BS 6891.

Safety

Gas person, your

The

in

interest, and

manufacturers

of

this

local

and

bye

laws

British

(Installation

accordance

that

notes

appliance

Building

of

the

Standards

and Use)

with

the

of

safety

must

be

in

Regulations,

local

water

and

Codes

Regulations

above

regulations. Failure

to

ensure

compliance

not

be taken,

DATA

Flues

Flue

and

Secondary

Hot

Water

Bypass

Inspection

Adjustment

accordance

Building

undertaking.

of

Practice: BS 6798:1987, BS 5449:1:1990,

1984:

in

any

way, as

Vent

Supply

It

with

Vertical

Secondary

Feed

Secondary

(Secondary)

with

the relevant

Standards

It

should

is

the

to

install

the

law.

overriding

Flues

be in

law

that appliances

System

requirements

(Scotland)

accordance

all

gas

statutory

correctly

of

(Consolidation),

with

the relevant BS

appliances

could

obligations.

the

Gas Safety

5546:1:1990,

are

installed

lead

(Installation

current

lEE

recommendations

BS

5440:1:1990,

by a competent

to

prosecution.

and

wiring

It

is

of

in

TECHNICAL

Table

1

MODE

HEATING

RANGE

DOMESTIC 23.44

HOT WATER

Note:

The

pressure

DATA

OUTPUT

kW

8.79

11.0

13.0

15.0 151195) 19.6

17.0

19.0

23.44

test

point

NOTE: THE

HAND

NOMINAL

(Btu/h) (30000) (37545) 14.7

1443701

(58020) (64845) 24.2 (80000) 29.3 (80000) 29.3

is

located

DATA

SIDE.

BOILER RATINGS (10

on

the

PLATE

kW

12.0

17.1

21.9

gas

IS

POSITIONED INSIDE THE APPLIANCE

minutes

INPUT PRESSURE GAS RATE

(Btu/h) (40955) 2.2 (50170)

(58360) 4.4

(66555) 5.8

(74745)

(82595)

(1

00000)

(1

00000)

valve

(See

fig.

31a).

after

lighting)

BURNER SETTING

(in.

m bar

3.2

7.3

9.1

14.3

wg)

(0.88) (1.28) 1.36 (1.76) (2.32) 1.81 (2.92) (3.64) 2.25 (5.72) (5.72)

AT

m

1.11

1.59

2.03

2.72

THE FRONT LEFT

3

/h

ift'ih (39.4) (48.3) (56.2) (64.0) (71.9) (79.5)

(96.2) (96.2)

I

2

Table 2

SPECIFICA

nONS HEATING FLOW HEATING RETURN SAFETY VALVE COLD

FEED COLD WATER DOMESTIC

MAINS

IN

WATER OUT

15mm

GAS INLET HEIGHT WIDTH DEPTH WEIGHT

95kg (2101b) PRIMARY CAPACITY *MAXIMUM *MINIMUM

STATIC HEAD

STATIC HEAD 1000mm (39in) CIRCULATING PUMP EXPANSION VESSEL 12 OUTPUT OUTPUT CH

DOMESTIC HOT

MAXIMUM

TO TO

CONTROL

DOMESTIC HOT WATER FLOW RATE

HEATING

MAXIMUM

DOMESTIC HOT WATER 23.4kW (80,000 Btu/h)

THERMOSTAT-

WATER FLOW

MAX.

TEMPERATURE

RATE

(35°C

RISE)

Nominally

28mm 28mm 22mm 22mm

COPPER COPPER COPPER COPPER

TUBE TUBE

TUBE

COMPRESSION - SUPPLIED 22mm 22mm

860mm 550mm

600mm

empty-

COPPER COPPER

TUBE

TUBE (33.9in) (21.6inl

(23.6in)

147kg (3241b) full

48 litres (10.6 gal)

25m

(81ft.)

Grundfos

litres

15-60

charged

0.5

bar

23.4kW (80,000 Btu/h)

Nominally

9.6

15

82°C

(180°F)

litres/min + 15%

litres/min

(3.3

gal/min)

(2.1

gal/min)

±15%

*

Appliance

static

heads

are

measured

from

the top

of

the

casing

to

the

highest

point

of

the

Table 3

HORIZONTAL VERTICAL

FLUE WALL

DETAILS-

OR

See Notes

CEILING-

Below

REAR FLUE PRIMARY FLUE

HOLE DIAMETER FOR AIR DUCT 125mm (Sin) WALL HOLE DIAMETER FOR SEALING RING 150mm (6in) MINIMUM FLUE MAXIMUM FLUE

LENGTHS WITH EXTENSION KIT 1

FLUE

If a flue

FLUE

extension

KIT ONLY

LENGTH-

is

required

MAY

BE

STANDARD FLUE KIT 100mm (4in)

1

STANDARD FLUE KIT

(See

USED

Section

PER

APPLIANCE. Part No. ZAGAS066

9)

it

may

be

obtained

from

Worcester

OOOmm

001

to 2000mm

(39

to

Heat

73in)

Systems

Table 4

HEATING OUTPUT

kW

8.8

11

13

15

17

19

23.4

Btu/h (30,000) (37,500) (44,350) 4.3 (51,200) 3.8 12.6 14.33 (58,000) 3.3 10.9 (64,800) 2.2 7.2 (80,000)

AVAILABLE PUMP

HEAD

METRES

5.1

4.7 15.5

1.5 5.0

FEET

16.6

14.1

HEADS

MIN. FLOW RATE OPTIMUM

LITRES/MIN.

8.41

10.51

GALUMIN.

1.89

2.36

12.42 2.79

3.22

16.24

18.15

22.35

3.65

4.08

5.02

system

(See

125mm

Fig_s.

24.

(Sin)

1557mm (61.3in)

(39in) 2000mm (73in)

2001

to

3000mm

(79

to

118in)

Ltd. ONE

TEMPERATURE

15°C

between

heating

flow

EXTENSION

RISE

and

return

and

25)

3

1.

GENERAL

IMPORTANT: to

instal a sealed

ondary

can be

the

(i) Sealed

(ii)

(iii)

FOR FURTHER ADVICE

SYSTEMS

1.

(a)

system

used,

following:

secondary Open (Section Open feed)

HIGHFLOW

An exchanger

primary

vented

11)

vented

secondary.

LTD.

induced

INFORMATION

Although

via

i.e.

(Section

3.5 RSF INCORPORATES

primary

the

system and

primary

or

primary

draught having

the

appliance

water

mains

arrangement

open

1 0)

or

and

CONTACT

fan, a

a

maximum

system

supply,

vented

mains

open

low

includes

and

feed

only

one

must

(i.e.

cistern

feed

vented

WORCESTER

thermal

capacity

heat

23.4kW (80000 Btu/h).

(b)

Either a horizontal flue

system

(c) A

standard 100mm kit

from

length

A

standard diverter

The

kit tween appliance 2001mm option).

(d) A

heatbank

(10

gallons) tioned to

water Secondary through

{e) A

diverter

domestic

(f) A

circulating

(g) A

(h)

(j)

(k)

{I)

2.

multifunctional tronic domestic

provides

Boiler stats estic

A User/s or

heating

as an

An

expansion valve to

be

An

electronic

ables utes

after INSTALLATION GREAT CARE

NO

FOREIGN SYSTEM. THIS APPLIANCE.

3.

NATURAL The boiler requires 2.72m'/h (96.2ft'/h) of gas. Meter and

supply pipes

in

gas in tho house. nominal pressure of 20 equivalent valve. should be inspected and tested for soundness and purged in

accordance with the recommendations of BS 6891.

-to

duct

{4in)

1001

is

available

duct

intended

will

enable

1557 (61.3in)

top

(59in)

having a nominal

inside

heat-exchanger

supply

the

heat

valve

hot

control

hot

automatic

and

hot

providing

hot

water.

Operating

and

optional

and

auto

connected

the

pump

each

GAS

must

addition to the

The

to a pressure of about 18:5-19

The

complete

(rear

order.

kit

to

1000mm

mm

(39in)

as an

kit

for

outlet.

to

3000mm

of

circulating

the

appliance. A copper

exchanger.

to

water

pump.

system

water

control

Switch

water. A programmer

extra.

vessel,

air

vent

to

a sealed

pump

to

run

operating

WARNING:

MUST

MATTER

COULD

SUPPLY

be capable of delivering this quantity of

meter

outlet)

for

horizontal

{39in).

to

option).

for

vertical

installation

the

diverter

and

2000mm

(An

is

domestic

direct

the

or

central

HIGH/LOW

to

and

central

ignition.

temperature

for

pressure

to

enable

delay

on

for a period cycle.

BE

TAKEN

IS

CAUSE

demand

outlet governor

mbar

installation,

or

vertical

flue

lengths

(An

2000mm

extension {118in) is

primary

fitted

boiler

heating

control

central

selection

water

control

LEFT IN THE

from any other appliances (Bin wg) at the appliance,

extension

{79in)

flues,

complete

within a roof

to

be

installed

(79in)

duct

available

capacity

hot

finned

into

the

hot

water

output

as

gas

valve

individually

heating.

control

heating

of

kit is

gauge,

pressure

the

primary

system.

board

of

TO

ENSURE

DAMAGE

must

mbar

mcluding

about 5 min-

water

required.

The

the

facility

the

of

these

be

one

feed)

secondary

(i.e.

cistern

HEAT

output

fanned

from

duct

maximum

with

space.

above

kit

from

as an

of

45

litres posi-

water

heatbank.

passes

either

and

elec-

system

thermo-

and

dom-

water

only

available

relief

circuit

which

THAT

WATER

TO

ensure a

at the gas

the

meter,

sec-

of

heat

of

be~

the

to

the

en-

THE

ELECTRICAL SUPPLY

4. Mains

See

with

continuous.

5. OPEN The

sealed used ing

its

taken

6.

CONTROLS All

controls

in

the

There

thermostat

supply

Section

the

VENTED

appliance

by

not

is

240

13.

appliance

SYSTEM

water

connection.

'Short

is

system.

carefully

to

distort

included

List

provision

to

be

V,

........

The

length

is

rated

supplied

An

removing

See

the

with

of

Parts'

for a room

fitted

50 Hz, 160

of

supply

at a

ready

open

vented

the

safety

Section

pipe.

the

appliance

included

the

appliance.

thermostat

to

watts

temperature

for

11. Care

13.

Thermostatic

system; this

DRAINAGE

7.

A

drain

primary

vessel

type

to

radiator

however, a suitable

of

control.

cock

is

heat

bank

drain

See

fitted

to

water

valves

Section

in the from

can be

by-pass

the

pipe

sealed

the

15.

system

boiler

bank. (Fig. 46)

8.

PACKAGING

The

appliance

arate

package

or

vertical

flue

terminal

flue)

together

materials,

2.

SITING

(Refer also to sections

1. The appliance is floor standing and the

2.

level.

and

The

following

servicing and ventilation:

is

contains

flue

kit. Each kit

(horizontal

with

etc.

THE

despatched

either

includes

flue)

the

necessary

APPLIANCE

5,

6,

7 and 8).

clearances

in

the

must

one

standard

either a balanced

or

diverter

duct

be

(a) Above the appliance: Servicing 450

Ventilation 5 mm (0.2 in.)

(b) In front of the appliance: Servicing 600

(c) Left and right-hand side: Servicing

Ventilation 75

20

Ventilation 20 mm (0.8 in.)

NOTE: available tion

3.

4.

NOTE: building Gas Framed sought

3.

Care

9.

The

chosen satisfactory if a horizontal

The

chosen satisfactory down flue

system

If

publication

Housing"

from

REMOVAL AND

See Fig. NOTE:

front panel, aid

It is

cover,

left

installation.

must

at

either

draught

the

appliance

it

should

the

CABINET

1. necessary

and

right

be

taken

side

for

position

balanced

flue

system

position

secondary

free

to

be used.

be

fitted

"Guide

Ref

local

zone. See

DM2.

Region

is

OF

to

may

be

hand

to

installing

must

flue

must

flue

is

to

be

in

for

Gas

If

FACIA

remove necessary

side

ensure

the

allow

to

be

allow

terminal

Section

fitted

Installation

in

doubt

British

the used

the

in a timber

termination. is

accordance

of

PANEL

the

to

panels

and

adequate

Gas.

cabinet

fused

at 3A.

cable

provided

of

aooc

connection

system

valve

are

in

See

used

is

essential

connecting

and

package. A sep-

work,

floor

left

to

mm

mm mm

mm

boiler.

provision

See

OR

provision

discharge

8,

with

advice

remove

lower

to

can

and

seal-

should

specified

this

leaflet.

and

frost

Section

in

with

expansion

the

heat

horizontal

(vertical

sealin~1

must

be firm

allow

(18 in.)

(24 in.) (3 in.)

(0.8 in.)

space

See Sec-

of

Section

of in

if a vertical

framed

the

British

in

Timber

must

top

cover,

the

facia

grille

a

be be

the

thE!

for

is

a

6,

a a

b~3

to

4

Fig. 1

Cabinet -Control

TOP TOP

COVER COVER

A

B

Panel

RETAINING LUGS FIXING BOLT

c FACIA FIXING SCREWS

D DHW AND

MOUNTING

CONTROL PANEL FIXING SCREWS

E

CONTROL PANEL SUPPORT BRACKET

F

AND

LEFT

G

SIDE PANEL BRACKET FIXING SCREWS

H

RIGHT HAND SIDE PANEL FIXING SCREWS

J

K LOWER FRONT GRILL

KICKSTRIP FIXING SCREWS

FRONT COVER {NO FASTENINGS)

L

CH

THERMOSTAT

BRACKET FIXING SCREWS

SCREW

HAND SIDE PANEL FIXING SCREWS

and

Facia Fixing

Screws

A

J,C

c

L

(a)

Remove the

Remove pletely

cover.

(b)

Pull

disengage enough

Undo

(c)

grille

(d) Pull

five

the

it

to

forward come

programmer,

drawn

in

terminal

the

numbered halves removed

(e)

Remove

retaining two screw

'J'.

Draw

NOTE:

single to strain

4.

(a) circulating frost appliance bore

The

posidrive

hold

should

SYSTEM

The

thermostat,

or

the

base

and

the

See

Fig.

up

the

to

disengage

the

five

kick

strip.

off

the

screws

side

the

micro-bore

panels

the

base

until

away

it

forward

heating

of

the

completely. the

the

M5

slotted

retaining

the

control

panel

be

appliance

pump

will

operate

'C';

rail

14

cabinet

lifting

bolt

cabinet

'B'

front

upwards

top

retaining

cover

and

cover

by

outwards.

by

the

1.

front

edge

of

the

fasteners.

screws

two

thermostat

two

and

three

of

the

it

clears

complete

if

fitted.

enough

positioned

thermostat.

to

17

terminal

two

remaining

top

of

head

the

top

side

panels

panel

screw

'F'. (See Fig. 1).

during

placed

on

Draw

it

at

the

'K'

securing

underneath

control

the

side

with

Support

to

behind

inclusive.

rail,

(Fig. 37)

the

left

screws

of

the

forward

is

supported

installation

the

panel.

the

rear

holding

knobs the

ends

panel.

panels.

three

gain

The

enabling

posidrive

hand

and

right

and

only

cover

and

position

the access and

terminal

Separate

side

CONSIDERATIONS

includes a pump

is

required.

refer

satisfactorily

system.

to

When

Section

fitting a room

13,

on a two

pulling

slackening

front

of

sharply

cover

lift

clear.

the

lower

and

remove

of

the

facia,

Pull

the

The

facia

switch

facia

to

the

facia

screws

panel

single

posidrive

hand

side

lift

out.

in

position

This

is

and

no

and

no

Electrical.

pipe

firmly

com-

the

top

forward

front

the

facia

fixing

facia

will

or

having

the

plug

right

of

rail

the

two

to

be

'C'

and

the

panel

by

intended

undue

other

or

The

small

at

to

is

a

""

(b)

5.

1.

2.

Table

5

K

The

heatbank exchanger control the be For thermostat use, a heatbank. this

IT

system

domestic

turned

large

few

period.

IS ESSENTIAL TO FIT A BYPASS TO ALL

contains

which

provides

is

incorporated

hot

off

The

water

when a demand quantities should

minutes

be may

central

a

and

of

set

be

heating

finned

domestic

that

the

central

for

hot

water

at

maximum

required

will

gives

hot

water

remain

copper hot

to

SYSTEMS.

AIR

SUPPLY

The

room

not

If

the compartment, the

cupboard

one

room. communicate on effective

in

require a purpose

appliance

at

low Both

the

same

areas

which

permanent

or

level,

high

with

required

HORIZONTAL

the

appliance

air

vent.

is

installed

and

to

air

direct

low

same

outside

are

compartment,

either

the

wall

is

in a cupboard

vents

one

at

to

outside

level

room

or

air.

given

in

installed

are

high

air

must

The

Table

5 COOLING AIR REQUIREMENTS

HORIZONTAL

Position

Air

Vents

High

Level

Low

Level

of

AND

VERTICAL FLUE SYSTEMS

Air

from

room

2

264cm

7

)

{41

in

7

264cm

2

(41

in

)

Air direct

from

water.

priority

heating

is

the

and

re-heat

off

FLUE

required

level,

air

vents

both

minimum

5.

outside

132cm

{20.5in

132cm

(20.5in

heat

will

made.

control

after

the

during

does

and

or

to

must

2

)

2

7

)

A

to

or

in

a

be

6.

FLUE HORIZONTAL

TERMINAL

FLUE

POSITION-

IMPORTANT

1.

Flue length. See

tion,

regarding

note

standard

in

Section

flue

1,

General

assembly

and

flue.

2. The flue must be installed in accordance

recommendations

Minimum flue

siting

terminal:

TERMINAL

A-

Directly

window

brick

B-

Below drain

pipes

Below

c-

D-

Below

E-

From

vertical

soil

F -

G -

pipes From Above

internal

level

H-

From a surface

1-

From a terminal

J -

From

an

(e.g.

KL -

door, Vertically the

same Horizontally the

same

below

or

gutters,

eaves

balconies

ground,

opening

of

BS

5440:Part

dimensions

for

positioning

POSITION (See Fig.

an

open

other

soil

drain

or

roof facing a terminal

window) from a terminal wall

from a terminal

wall

able

opening,

or

external

facing a terminal

in a car

pipes

car pipes

or

into

e.g.

or

port

and corners

balcony

port

dwelling

on

2)

roof

on

1.

the

MIN

air

300mm

75mm

200mm

75mm

300mm

600mm

1200mm

1200mm 1500mm

300mm

GENERAL NOTES

1.

The

terminal

bustion

2. In

certain

and

positions

should

3.

If

the gutter nium

shield

to

the

(Dimensions 8 and

4.

If a terminal above a surface suitable ive

guard

Limited, Guard The

terminal

using

the

corrosion

metrically and

spaced

imum

5.

The

air

the

boiler combustible protection

5440:1

must

products

weather avoided.

within

of

guard

is

available

vale

guard

three

resistant

positioned

such

must

of

1990,

where

is

at

is

must Rise,

brackets

the

material.

combustible sub-section

be

terminal or

underside

Reference:

between

inlet/products

be

positioned

can

disperse

conditions a terminal

this

fitted

450mm

least

of

the

C in Fig. 2).

fitted

to

which

be

from:

Tonbridge,

GC

393

must screws.

about

that

end

outlet

not

be

freely

could

within

850mm

of

painted

750mm

less provided. A terminal

there

of

closer

Detail

long

gutter

than 2 metres

people

Tower

553-

Type

be

securely

provided,

The

guard

the

is a

the

terminal

duct

than

recommendations

material

3.3

such

that

at all

cause a nuisance

of a plastic

eaves, an

should

or

painted

have

access

Flue

1TB.

K2.

fixed

suitable

terminal

gap

of

and

the

50mm

are

Components

must

and

given

TN9

IMPORTANT

It is

absolutely

products

terminal

adjacent doors,

other

ced

ventilation/air

should

immediately

occur,

cannot

of

combustion

building

sources

the

and

ESSENTIAL

re-enter

the

through

of

natural conditioning. appliance

problem

to

ensure,

discharging

building ventilators,

air

infiltration

If

this

MUST

rectified.

or

be

Informa-

extension

with

the

balanced

DISTANCE

(12in)

(3inl (Sin) (Bin)

(3in)

(12in) (12in)

(24in) (47inl

(47in) (59in) (12inl

the

com-

times.

may

steam

alumi-

be

fitted

surface

(78.6in)

then

protect-

Terminal

to

the

wall

plugs

and

be

sym-

assembly

50mm

min-

the

guard.

terminal

(2 in)

on

in BS

in

practice, from any

other

windows,

or

for-

eventuality

turned

of to

the

off

7.

AIR

SUPPLY

1.

The

room

in

appliance

low

level,

Both

high

with

wall

to

required

which

or

the

require a purpose

2.

If

the compartment, the

cupboard

one

at room. municate

same areas

REQUIREMENTS,

3.

ALL

installations

designed

direct

THE

air

with

outside

MINIMUM

vents

VENTS WITHIN A ROOF SPACE

4.

The

roof

the

any

space

off

completely

room,

other

cupboard

is

room.

sealed

(a)

appliance

(b)

8.

CONNECTION SECONDARY

The

components

are

supplied

the

top

ensions

must

be

such

as

A

secondary diverter. size

125mm adaptor diameter complete

boiler

shown

positioned

loft

This

will

must

and

flue

in Fig. 3.

insulation.

flue

component

(5in).

need

not

flue

system

up these

must

If

VERTICAL

the

appliance

air

vent.

is

permanent

installed

compartment,

either

direct

and

low

same outside are

room

air.

given

Section

must

in

the

air.

air

level

in

5.

be

roof

vents

one

to

or

The

Table

provided

space,

FLUES

is

installed

in a cupboard

are

at

high

outside

air

vents

must

both

minimum

5,

COOLING AIR

with

communicating

EFFECTIVE AREA REQUIRED

IS

516cm2 (80in

containing

installed

to

and

must

outlet,

such

be

flue

to

be

decreased.

must

from:-

Note

that

fitted

will

pipe

fitted,

the

diverter

or

compartment

and

OF

PRIMARY

VERTICAL

including

be

in

to

be

the

installed

accordance

that

the

it

will

not

to

the

accept

flue

BS 4543 is

but

the

The

in

accordance

draught

be

top

nominal

installation

in

FLUES

vertically

with

obstructed

of

pipe

used,

does

required

level,

air

or

must

be

on

effective

purpose

FOR

2

must

which

AND

diverter

above

the

diverter

the

draught

to

BS then internal

of

with

not

and

to

com-

the

AIR

).

the

dim-

715

the

BS

or

in

a

be

by

an

5440:1.

The

secondary

ported at

out

a

of

Table

and

Horizontal

least

in

accordance propriate No

part

combustible

7

Max.

secondary

if

set

to

The

flue

sure

that system operating

when

NOTE:

openings within

the

minimised,

of

lengths

The

applicable-

The

user

the

roof

space

space of

the

compartment -if A

around

flue

the

exit

runs

and

point

at

which

the

flue material.

minimum

condensate

flue

6m

(20ft)

recommended

the

conditions.

required

appliance

permanent,

diverter

MUST

be

which

applicable.

at

least

draught

system

from

bends

and a spillage

with

system

length

CH

does

within and

NOT

instructed

may

250mm

diverter

must

the

roof

should

BS 5440:1. Fig. 3

to

apply

shall

Max

input

if

set

above

not

form

operates

purpose

the

roof

any

compartment

BECOME BLOCKED.

not

cause

(10in)

with

be

space

ideally

test

the

test.

be

within

secondary to

maximum

1Om

are

in

the

under

designed

space,

to

store

an

obstruction,

radius no

obstructions

adequately

water

proofed.

be

avoided,

must

be

carried

shows

25mm

flue

length

CH

(33ft)

intended

secondary

all

approved

ventilation

the

openings

ventilation -if

items

or

shall

be

provided

(Fig. 3).

sup-

but

an

ap-

(1.0in)

input

to

en-

flue

within

in

the

6

Fig. 2 Siting of terminal

Horizontal Flue

A'

j

GJ

~

Dj

~HI'

/

'

-'l

..

'

: .Ji

, , I I

J

, I

I.

F

I

l]

BC~

'

A

~

'

\

~J

G

'j

r·E

I

~

F'

,,

L'hl

v .

!

I

/

llF

IK

•

IK

I

Fig. 3 Position of Vertical Primary

TWIN IS

DRAUGHT DIVERTER

(5in) SOCKET OUTLET CLEAR SPACE

RADIUS DIVERTER WITH

OBSTRUCTIONS

STANDARD MINIMUM

1557mm

MAXIMUM

2000mm

WITH EXTENSION KIT H ~ 3000mm

Flue and Secondary Flue See also

WALL

RECOMMENDED

WITH

AROUND

(61.3in)

(79in)

MAXIMUM

Fig. 17

SEC. FLUE

125mm-------l-·f"=Y

250mm

NO

FLUE KIT

HEIGHT H

HEIGHT

(118in)

-------+

(10in I

TERMINAL

(NOT

SUPPLIED)

.•

~

..

. M .

H

··1-.,+-~

45mm:

(1.8in)

l_

BOTTOM SOCKET

OF FLUE OUTLET

GENERAL GUIDANCE · SITING OF VERTICAL

CHIMNEY

PITCH

EXCEEDING 30°

T

CEILING FLUE SEALING PLATE

1;

860mm

(33.9in)

PITCH

EXCEEDING 30° LEVEL

NOTE: A spillage test must be carried out at the diverter

FLUE

NOT

HERE,

TERMINAL

ON

RIDGE

AT

OR

ABOVE

RIDGE

in

accordance with BS5440:1.

ROOF SPACE VENTILATED TO

OUTSIDE AIR SECTION 7.3

NOT

Dim. Y 1m

ABOVE ROOF

INTERSECTION

Dim Y

ABOVE ROOF

INTERSECTION

ON

RIDGE

250mm

(3.3ft)

(lOin)

7

9.0

INSTALLING GENERAL

If a HORIZONTAL 2,

5,

6,

9.1

and

If

a VERTICAL FLUE is

7,

8,

9.2

NOTE: TO

The left

A installation.

then In

particularly servicing pre-plumb (Fig tion. before whether tion

A

facilitate Compression

nections ing.

1.

2.

3.

4.

MORE

INSTAL

space

hand

description

the

some

5)

to

If

so assembling

1 (c)

knock-out

Unpack

required) dosed standard

moved. Remove

cabinet

The flue

sealed

quired To

gain

move

9.3:

and

9.3; THAN

THE APPLIANCE.

required

side

and given

If

connections

space

required

circumstances

where

have

been

the

appliance

the

boiler

refer

to

or

not

an

and

Section

panel

vertical

fittings

to

allow

the

appliance.

the

standard

and

check list.

flue

the

as

described

boiler

is

outlet

configuration;

off

with

refer

to

access

the

access

FLUE is

also

to

also

Fig. ONE PERSON

for

150mm

in

Section

minimum

used,

pipework

Section

the

extension

2.

is

provided

pipe

connections.

may

for

the

check

Ensure

assembly

top

cover

supplied

blanking

Figs 6

to

the

cover.

THE

to

be

installed

3.

(6in) at

are

installation

when

clearances

it

may

and

fit

before

9.3

and

system.

kit is

in

be

fitting

flue

kit

the

all

and

in

Section

suitable

the

plates.

and

7.

top

Fig.

installed

and

9.3 made

installing

used

contents

cardboard

the

flue

6.

Figs. 2

installation

for

flue

APPLIANCE

refer

4. refer

MAY

is

50mm

the

right

covers

in a different

be

found

unions

moving

make

Check

required.

the

cabinet

on

of

the

and

flue

front

3. for a horizontal

vertical

If a vertical

outlet

to

BE

(2in)

hand

one

may

be

the

for

access

necessary

and

stub

it

the

connections

to

Refer

top

all

water

boiler

and

extension

against

packing

extension

panel

outlets

cover,

to Sections

Sections

2,

REQUIRED

at

the

side.

method

greater. appliance,

into

determine

flue

to

panel

servic-

the

from

first

of

way

and

to

pipes,

posi-

Sec-

to

con-

kit

(if

en-

in

the

is re-

the

rear

being

is re-

re-

(a)

Remove plates.

(b) Run a

(c) Fit

working

(d) Fit

NOTE:

THE FLUE

REFER

{EXTENSION

9.1.

1. Take

tions

2.

Determine boiler

NOTE: OF ASSEMBLING

bead

the

rear

the

blanking

push

fully

the

fully

into

THE ACCESS

SYSTEM

TO

SECTION 9.2a

REAR

account

Siting

the

Refer

to

quired

on

diameter.

NOTE:

If a core

is

made

imum

diameter

made

good

9.1a; 9.1b; 9.1c).

ropriate

assembly

Section

9.1a.

9.1b.

9.1

c.

REFER

THE

the

top

air

duct

of

silicone

flue

duct

and

air

plate

and

the duct

PANEL

IS

FITTED.

top

and

into

tighten

socket

{STANDARD

home

through

rear

air

the

socket

KIT)

Subsection

HORIZONTAL

of

the

appliance.

page 1 and

the

wall.

oversize,

before

the

section

TO

INSTALLATION

THE REQUIRED FLUE

requirements

Fig

Cut a hole

boring

tool

it

must

and

the

flue

length

below,

which

procedure.

100mm-1000mm 1001

mm-1200mm

1201

mm-2000mm

SECTION 9.3. COMPLETE THIS PART

and

flue

duct

sealan1

air

tighten

MUST

duct

the

3{a).

around

sockets.

rear

the

duct

blanking

the

BE

flue

clamping

socket

plate,

clamping

REPLACED

FLUE KIT)

FLUE

under

4.

Mark

the

flue

in

the

wall

is

not

be

inner

appliance

Length

AS

used

reduced

by

to

skin

of

the

is

installed

referring

details

the

L

(4in-39.4in)

(39.4in-47.2in) (47.2in-78.7in)

NECESSARY BEFORE

ARRANGEMENT.

blanking

the

inside

outlet

opening.

push

screw.

OR

Section

position

125mm

and

the

130mm

brickwork

to

the

correct

of

socket,

screw,

it

WHEN

9.2b

2 -

re-

(5in)

hole

max(Sec-

app-

flue/

Fig. 4 Wall

Dimensions

preparation · Rear

mm

(in)

1----

,.-t..""_

.,(---

!.._-----

600 {23.6)

)

--....J---....1

outlet

r-

-,

r~~-

' ' '

~----~

--

- -

-1{~~

)r

5

~

.L~

1:1.

I

~

TOP AIR

{DEPTH

HOLE TO ACCEPT REAR AIR

WALL INCLUDE FINISH, INSIDE OR

OUTSIDE

DUCT

18mm

CUT

THROUGH

THICKNESS TO

ANY

SURFACE

SOCKET {0.7in)

~

REAR AIR {DEPTH

DIMENSIONS VARY ANY REMOVED SHEET IS PLACED BETWEEN THE APPLIANCE

DUCT

18mm

DEPENDING

FLOOR COVERING IS

SOCKET

{0.7in)

ON

AND/OR

AND

FLOOR

PAGE 1

ON

WHETHER

INSULATING

THE FLOOR

LEVEL

INSIDE PLASTER

MAY

WALL

DUCT

OUTSIDE RENDERING

IF

APPLIED

8

Fig. 5 Rear View of Boiler Pipework and Flue Connections

NOTE: ALL DIMENSIONS ARE NOMINAL mm (in) A CENTRAL

B SAFETY C GAS INLET (22mm)

DOMESTIC COLD WATER

D E DOMESTIC HOT WATER OUT (22mm) F CENTRAL G VENT AND FEED (22mm) H REAR FLUE CONNECTION (Centrelines)

HEATING RETURN (28mm)

VALVE (22mm)

HEATING FLOW (28mm)

r

r--·

I

=

-:-·.

---

IN-

R'h ('/,in BSP)

--~

r--:_:

~

•

G & B 200mm (7.9in)

D

170mm

(6_7in)

E 135mm

(5.3in)

F 90mm

(3.5~n}

A 60mm (2.4in)

~f

I

mn

~-g-~

.£

cr>LOcn~rn

<Drnoc<Jc<J

2.!-~~~'22.

E E E E E E E E E E

N 0

<r>mro~<D

<Dr-r-roro

:s

lO

o o

Fig. 7 Flue/ Air Duct Socket Clamping Screws

NOTE: A SIMILAR METHOD IS USED TO CLAMP

AIR DUCT.

REAR ACCESS TO THE SCREW IS

FROM THE TOP (FIG

VERTICAL AIR DUCT CLAMPING SCREW

THE

6)

_.----

__

_;;;____ DUCT SOCKET

VERTICAL AIR

[c

Fig. 6 Interchanging Positions of Air Duct/Flue Duct Outlet Blanking Plates

I

~..,

--550mm

H 377mm

{21.6in)--

(14.81n)

___,

-1

APPLY SEALANT OF

FLUE

REAR

FLUE DUCT

CLAMPING SCREW

AND

REAR BLANKING PLATE POSITION

AROUND

AIR DUCT SOCKETS

AIR DUCT

INSIDE

FLUE DUCT HOUSING

REAR

FLUE DUCT BLANKING

PLATE POSITION

tr

I

9

9.1

a BOILER FLUE

NOTE:

1.

Cut

(a)

Measure (Fig 4, 8 (4.5in)

(b)

Reduce

that

REAR

100mm-1000mm

An

extension

the

air

diameter

one

duct

the

and

the

end

wall

15).

air

OUTLET

of

NOT CUT FROM THIS END

2.

Cut

the

flue

duct

(a)

Take

wall

overall

required.

the

from

to

Figs 6 &

screw to

be

to

the

duct

only

passed

into

(Fig 8)

flue

{16in)

housing

in

front

the

provided.

the

panel,

rear

flue

rear

air square

front

of

duct

into

the

clamping

concentrically

the

hole

one

flue

socket

Make

the

with

of

the

and

check

flue

Slide

rolled

as a

3mm

drill

two

No

THAT

from

through

100mm

duct

the

section

the

thickness

length

flue

either

sufficient

pulled

rear

on

wall

should

through

the

duct

prior

of

backing

adhesive

around

of duct

duct

the

{1.6in) in

through

the

top

screw.

in

end

duct

tighten

sure

within

appliance

the

wall.

terminal

the

stop

guide

supplied.

6 x

BEEN

outside {4in) is

inside

air

the

duct

(b)

Reduce cutting

Refer

3. ping plate access

Depending

flue

(a) Be

fixed

housing

(b)

If

the 400mm duct tion

4.

Remove gasket press back

Either

(a)

Apply a bead the the

position, in pane140mm

flue

home

through duct

itioned

and

or

(b) Push

rear duct screw. centrically

Move face, front

hole

5.

Fit

the

holes.

the

duct

the

with (Fig 10).

6.

RECHECK QUIRED HAVE

7.

Working assembly about of

flue over provided curately.

ASSEMBLY

(4in-39.4in}

kit

is

NOT

required.

to

length

as

thickness

This

air

duct

the

to

length

of

duct

end.

7.

Slacken

out

flue

thickness

the socket or

is

it

may

to

the

inner

Position

backed

the

silicone

socket

socket.

to

the

hole

the

rear

air

duct

the

wall.

of

the

socket.

the

back

Allow

the

duct

into

flue

channel.

drill 10mm

ANY

the

of

flue

and

follows:-

Land

is

the

overall

required.

'A'

to

L +

duct

has

OF

as

follows:-

Land

add

60mm

to

'C'

to

(Fig 9).

the

to

allow

of

its

socket.

duct

clamping

either:-

relatively

paper

into

terminal

through

STUB

and

wall

from

at

the

be

fixed

moving

wall

from

the

side

rear

flue

sealant

and

Move

wall

face,

in

the

wall.

front

of

wall

and

flue

duct

socket

Make

sure

within

the

flue

duct

Working

the

rear

flue

duct

rear

air

duct

position,

panel

about

the

flue

is

positioned

the

end

Using

Screw self-tapping

PIPE

face. (Fig 8).

gasket

into

the the

MADE. (SECTION 9.3).

pass

the hole. A flue allowed terminal

duct

connected

flue

duct

add

28mm

length

28mm

two

(1.1in).

holes

THE DUCT.

51mm

L +

51mm

vertical

air

This

space

outside

of

short

directly

the

boiler

the

firmly

outlet

around

the

standing Position

watl

push

socket.

tighten

the

rear

fully through

flue

is

socket. square

40mm

duct

of

the

holes

flue

assembly

screws

(2.0in).

(2.38in)

air

duct

will

screw.

available

the

e.g.

to

square

as

shown,

against

(Fig 8).

the

appliance

face. Pass

the

flue

duct

air

duct

home

the

duct

positioned

to

pass

concentrically.

air

terminal

diameter

the

rear

the

CONNECTIONS

air

duct

and

expansion

for.

The

engage

have

short to

been

will

(1.1in).

of

110mm

drilled.

This

(2.0in)

duct

clam-

blanking

facilitate

and

flue

less

the

into

sealing

inside

centrally

the

end

Working rear

is

socket

into

top

clamping

to

the

(1.6in)

into

duct

up

in

the

together

provided.

terminal

joint section

and

the

boiler,

cut

Note.

DO

is

flue

by

the

then

duct

than

flue

posi-

then

the

of of

into

back

the

fully

flue

pos-

the

air

con-

wall

in

the

with

to

air

with

RE-

of

push

ac-

Fig. 8 Rear Flue

Application

FLUE DUCT HOUSING

CLAMPING

,..--------------,\1

SCREW

P~b.R

FLUE

OUTLET SOCKET

SEALANT

SEALING GASKET

BLANKING PLATE REMOVED FROM TOP AIR DUCT INLET SOCKET

ACCESS PANEL, WITH SCREW

REAR

AIR DUCT /

FOR

TOP FLUE OUTLET CLAMPING SCREW

CLAMPING SCREW

OUTER WALL

FACE

POSITION

SEALING GASKET

AROUND

Fig.Ba

REAR

FLUE OUTLET AS SHOWN

OUTER

PLAN VIEW

TOP AIR/FLUE DUCT CLAMPING SCREWS

BLANKING PLATE " FITIED

IN TOP FLUE

OUTLET SOCKET

M5

SLOTIED

HEAD FIXING

WALL

SEALING

GASKET

/

,,

"

10

8.

Move

the appliance into its final position. The air

should be pushed fully home into the air duct

duct socket. The back of the socket should be flush with

the

wall face, compressing the sealing gasket (Fig 8).

Tighten the air duct clamping screw.

Fig. 9 Rear flue application

FOR

WALL

THICKNESSES

100mm

to

1000mm

(4.Q;n

9.

Run

a bead of silicone sealant around the inside of the top air duct socket. Refit the blanking plate, pushing

air duct clamping screw.

Note.

with a

wall

to

39.3;n) USE THE

it

down until it

The

rubber

the

terminal

seai.See Fig.8a

is

REFER

sealing

fitted

to

this

STANDARD

fully home. Tighten the top

TO SECTION 9.3.

ring

only

may

appliance

FLUE KIT

to

be used

provide

IMPORTANT:

ENSURE END

IS

REFER

SQUARE

TO INSTRUCTIONS IN SECTION 9.1a BEFORE CUTTING AIR

AND

FREE

r * OVERALL

110mm

DIAMETER

Fig. 10 Rear flue duct assembly

(4.S;n) [I A

~------------------------~

~*OVERALL

LENGTH~

~--------c--------~~

CUT FLUE DUCT TO REQUIRED LENGTH FROM EITHER END. ENSURE END

FOR

WALL

IS

SQUARE

THICKNESSES

Air duct - Rear flue application

OF

BURRS.

LENGTH~

Flue duct - Rear flue application

AND

FREE

100mm

L PLUS

OF

to

L PLUS

51mm

BURRS.

1000mm

28mm

(2.0;n)

(4.Q;n

(1.1;n)

to

39.3;n) USE THE

~

0

I

OR

DO

NOT

WITH

60mm

(2.38;n)

DIAMETER

STANDARD

FLUE DUCTS

CUT FROM THE END

TWO

HOLES

FLUE KIT

IMPORTANT:

FLUE DUCT

;..--*OVERALL

3

~

~nT

j

l-

6 x

USING

10mm

* OVERALL

INTO

THE HOLES ALREADY IN THE END

3mm

SUPPLIED.

9

1

FIT FLUE STOP CHANNEL. TERMINAL

SCREWS

TERMINAL

WITH THE

No

REFER

TO

INSTRUCTION IN SECTION

A FLUE DUCT EXPANSION

100mm

PROVIDING THE AIR ACCURATELY CUT

TWO

No.6

SELF

FLUE

AIR DUCT

x 1Dmm

TAPPING SCREWS

9.1

a BEFORE

(4;n) OVERLAP IS

TO

\

LENGTH~

END OF AIR DUCT. SLIDE THE FLUE

DRILL SUPPLIED. SECURE THE

L PLUS

51mm

28mm

(2.0;nl--

(1.1;n)

TERMINAL

OF

THE AIR DUCT, DRILL THROUGH THE FLUE

ASSEMBLY

ROLLED STOP

CHANNEL

INTO

THE AIR

TOGETHER WITH THE

ASSEMBLY

JOINT

OF

ALLOWED

AND

FLUE DUCTS

THE REQUIRED LENGTH.

DUCT

APPROXIMATELY

FOR

ARE

FLUE

TERMINAL

UP

TO

THE ROLLED

TWO

SELF TAPPING

11

9.1

b BOILER

REAR

1001mm ~ 1200mm

NOTE:

1.

(a)

(b)

{c)

(d)

(e)

2.

3.

(a)

(b)

(c)

(d)

(e)

(f) Refer

NOTE:

passed (9.1 access duct section

4.

Use

Cut

the

Measure

This

is

air

duct

Reduce

900mm (Fig. 11)

Fully

engage

into

the

Reduce cutting overall

Using

'8'

as

the

drill

a

smear previously and

secure

(F1gs

11

Slide

the

'A',

to Using drill

through supplied. No.6 x 10mm

Cut

and

Take

the

is

the

duct

required.

Reduce 900mm

Fully

engage

expanded

Reduce cutting

length.

Using 'D'

as a

the

drill

a

smear engaged with

two

clamping ing

plate ilitate Run a

the

rear

If

the

through

b.4

and

is

insufficient

work

is

Remove gasket press back

panel, Apply a bead the

flue Move face,

standing

wall.

Position

front

of

wall

and

duct

socket. tighten the

flue

rear

air

the

standard

air

duct

the

wall

the

overall

required.

the

length

{35.4in).

the

expanded

the

length

from

the

length

the

two

a

guide,

supplied.

of

silicone

engaged

with

& 12).

flue

the

rolled

the

holes

Secure

self-tapping

assemble

wall

thickness

overall

the

length

(35.4in)

end

the

length

from

the

(Fig. 11).

the

two

guide,

supplied.

of

silicone

end

of

self-tapping

to

Figs 6

screw

to

be

access

bead

of

air

duct

fully

the

9.1 b.6)

piecemeal,

added.

the

backing

provided.

the

adhesive

around

duct

and

the

appliance

the

wall

push

Working

the

rear

duct

socket

FLUE

flue

to

length

thickness

length

of

Cut

surplus

end

of

end

WITHOUT

(Fig.11)

holes

in

drill

two

Disengage

sealant

end

two

terminal

stop

channel.

at

the

flue

tt1e

the

flue

depth

of

by

cutting

either

end

of

flue

duct

of

the

plain

holes

in

drill

two

Disengage

sealant

flue

duct

screws

and

7.

sufficient

pulled

to

the

rear

silicone

socket.

assembled

hole

in

there

it

may

passing

paper

Position

backed

the

of

silicone

air

duct into

centrally

the

back

face. Pass

the

end

through

flue

dtJCt

is

positioned

and

ASSEMBLY

(39.5in-

kit

and

extension

as

follows:

L.

and add

of

110mm

the

extension

from

of

air

duct

of

air

duct

'B'

the

standard

holes

the

expanded

3mm

diameter

the

air

around

of

air

self-tapping

into

end

terminal

assembly

Land

60mm

the

end,

the

Slacken

out

MUST

rear

fully

the

duct

the

of

air

screws.

duct

as

add

(2.38in)

standard

from

either

of

flue

'D'

(Fig. 11).

extension

to

expanded

3mm

diameter

the

around

'C'.

Reassemble

supplied

to

allow

of

its

flue

duct

sealant

flue

and

the

wall

be

possible

it

through

from

the

gasket

side

flue

sealant

sockets. position, in

front

panel

about

the

home

the

clamping

concentrically

hole

open

duct

with

the

flue

the

socket.

round

as sufficient

outlet

around

flue

in

47.2in)

28mm

(4.5in)

air

plain

'A'

(without

(Fig. 11)

air

to

end

ducts

the

outside

'A'.

screws

end

'A'

the

together

{Figs. follows:

51mm

diameter

flue

end.

duct

flue required

end

ducts

the

(Figs.

vertical

the

air

clamping

the

air

ducts

described

to

the

square

as

firmly

(Fig. 8).

square

of

the

40mm

duct

into

top

air

screw.

the

wall.

flue

kit.

(1.1in).

diameter

duct

'B'

end

ONLY.

holes)

duct

'A'

the

required

of

air

holes

using

and

apply

of

Reassemble

supplied.

of

air

as a

guide,

3mm

with

11

& 12).

(2.0in);

duct

'C'

(Fig. 11).

'C'

into

duct

'D'

overall

of

flue

holes

using

and

apply

previously

and

secure

11

& 12).

air

duct

blank-

This

will

screw.

inside

are

to

below

access.

assemble

hole

as

sealing

shown,

against

the

inside

to

the

hole

in

(1.6}

through

the

rear

duct

socket Make within

to

by

duct

the

duct

drill two

This

flue

to

the

by

duct

fac-

of

be

the

each

then

the

of

wall

the

in

the

flue

sure

the

5.

RECHECK REQUIRED HAVE BEEN

6.

Working assembly about of

flue over provided accurately.

7.

Move duct socket. the

wall

8.

Run a bead the pushing air

duct

100mm

duct

the

should

The

face.

top

it

clamping

THAT

from

through

inside

section

the

appliance

be

back

Tighten

of

air

duct

down

ANY

outside

the

(4in)

the

of

flue

air

and

pushed

of

silicone

socket.

until

screw.

STUB

MADE.

pass

hole. A flue

is

allowed terminal

duct

flue

into

its

fully

the

socket

the

air

sealant

it

is

fully

PIPE

(SECTION 9.3)

the

air

duct

expansion

for.

The

will

engage

connected

ducts

final

position.

home

should

duct

clamping

around

Refit

the

home.

CONNECTIONS

and

terminal

joint

short

section

and

the

flush

push

boiiE!r,

been

The

air

screw.

inside

plate

the

to

have

into

be

the

blanking

Tighten

of

cut

air duct with

of

top

REFER TO SECTION 9.3

9.1

c BOILER

FLUE

ASSEMBL

V

REAR

1201mm-

NOTE:

kit.

1.

(a)

{b)

Use

Cut

the

Measure This

is

air

duct

Do

not

the

air

the

required.

reduce

(Fig. 13).

(c)

Fully

engage

into

the

expanded

(d)

Reduce cutting overall

Using

(e)

'B' the a previously and supplied.

Slide

2. 'A',

Using drill supplied. No.6 x 10mm

Cut

3.

(a)

Do

as a

drill

smear

secure

the

to

through

and

not

the

from

length.

the

guide,

supplied.

of

the the

assemble

reduce

{Fig. 13)

(b) Take (c)

If

(d)

(e)

the

Fully

engage

expanded

Reduce cutting length, tained.

Using

the

as a

guide,

drill

supplied.

smear

of

ged

end

the

two

wall

the

from

after

(Fig.13)

silicone

of

self

2000mm

standard

duct

to

length

wall

thickness l and add

overall

two

silicone

engaged

(Figs. 13 & 14)

flue

rolled holes

Secure

end

two

flue

length

(Figs. 4, 8

the

length

the

end

length

drill

tapping

of

the

end

(Fig. 13) holes

drill

Disengage

sealant

with

terminal

stop

at

the

flue

the

self-tapping

the

length

thickness

either

of

flue

of

the

plain

engagement

holes

two

Disengage

sealant

duct

screws

in

two

end

the

channel.

assembly

flue

end duct

in

3mm

'C'.

(4:,.3in-

flue

kit

as

follows:

of

110mm

and

of

the

of

air

duct

of

air

duct

the

standard

without

the

expanded

3mrn

the

around

of

air

two

into

the

end

o1'

terminal

screws.

duct

of

the

Land

of

'D'.

the

ex':ension

end,

until

of

the

expanded

diameter

the

around

Reassemble

supplied.

78.7in)

and

the

(4.5in)

16)

extension

'A'

(without

'B'.

air

holes

to

diameter

air

ducts

the

duct

'A'.

self-tapping

open

air

duct

with

together

(Figs. 13 & 14)

as

follows:

standard

add

51mm

flue

duct

(Fig. 13)

flue

the

required

the

two

holes

flue

ducts

the

previously

and

(Figs

extension

28mm

diameter

air

duct

the

end

of

holes

and

outside

Reassemble

end

of

'A'

as a

the

3mm

with

flue

(2.0in).

'C'

duct

ducts,

end

of

using

and

secure

13 & 14)

flue

(1.1in).

duct

'B'.

holes)

'A'

by

required

air

duct

using

apply

of

the

screws

air

duct

guide,

drill

the

two

duct

'C'.

into

the

'D'

by

overall

is

ob-

duct

'D'

the

apply

enga-

with

a

12

(f) Refer to Figs. 6 and

clamping screw sufficient to ing plate to be facilitate access to the rear flue duct clam

Fig.

11

Rear flue application

FOR

WALL

AND

THICKNESSES/FLUE LENGTHS

THE EXTENSION FLUE KIT

7.

Slacken the vertical air duct

pulled out of its socket. This will

allow

the air duct blank-

pin~

screw.

1001mm

to

1200mm

NOTE:

If the fully assembled flue and air ducts are to be passed through the (9.1c.4 and 9.1c.6) there access

is

duct work piecemeal, passing section

is

(39.4in

insufficient, it

added.

to

47.0in)

hole

in

MUST

may

USE THE

the wall

be possible to assemble the

it

as

described

be sufficient access. If

through the hole

STANDARD

as

FLUE KIT

below

each

IMPORTANT:

REFER

TO

o---

l-·-t-------900mm

r:

100mm

(4.5in)

DIAMETER

[

f============"jrj!;/~~r2~==~/

/

REDUCE THE LENGTH OF THE

EXTENSION AIR DUCT TO

900mm

FROM THIS SQUARE

REDUCE LENGTH OF DUCT FROM EITHER END. ENSURE END

IS SQUARE

(35.4in) CUT SURPLUS

END. ENSURE END

AND

FREE

OF BURRS.

~~:------*

.i_

i-o[-l-------900mm

60mm

(2.4in) I 1

DIAMETER

TO

900mm

AND

6::;:;:;:;:;:;:;============~~~=====;=====;=dl'.~

T

STANDARD

(3.5in). CUT SURPLUS A SMEAR

FREE

OF BURRS.

IS

INSTRUCTIONS IN SECTION

Air duct - Rear flue application

* OVERALL

DO

EXPANDED END

LENGTH~

(35.4in)-----~

NOT

CUT -

ON FINAL

SMEAR OF SILICONE AROUND STANDARD

Flue duct - Rear flue application

OVERALL

FLUE ON FINAL

LENGTH~

(3.5in) I

ASSEMBLY

AROUND STANDARD

OF

THE OUTSIDE OF THE ENSURE END IS SQUARE

DUCT.

9.1

b BEFORE CUTTING AIR

L PLUS

28mm

(1.1in)

....,._1

~

ASSEMBLY

THE OUTSIDE OF THE

DUCT.

L PLUS

SILICONE

APPLY A

SEALANT

51mm

(2.0in)

~~

APPLY EXTENSION

SEALANT

OR

FLUE DUCTS

EXISTING HOLES

FIXING

'-

REDUCE LENGTH STANDARD FROM

END

---,

SURPLUS FROM THIS END. AND

FREE

OF

AIR DUCT BY CUTTING

WITHOUT

1~

REDUCE LENGTH OF

PIECE

OF

BURRS.

FOR

TERMINAL

HOLES.

BY CUTTING

Fig. 12 Rear flue duct assembly

FOR

WALL

THICKNESSES/FLUE LENGTHS

AND

THE EXTENSION FLUE KIT

IMPORTANT:

A FLUE DUCT EXPANSION ALLOWED

FOR

PROVIDING THE AIR

STANDARD

REFER

JOINT

AIR DUCT

~F~LU~E~D~U~C~T~~E~XT~E~~~S~IO~N~~~~A~IR~D~UC~~~E~X~T~~~N~SI~O~N~~~~~§:==~£L,

~

23mm

(0.9in)

FIT FLUE

THE AIR DUCT EXTENSION

IN WITH THE DRILL SUPPLIED. SECURE

I SUPPORT SPIDER /

j

~*OVERALL

TERMINAL

* OVERALL LENGTH L PLUS

LENGTH~

INTO

END OF AIR DUCT EXTENSION UP

AS

A GUIDE DRILL

1001mm

TO

INSTRUCTIONS IN SECTION

OF

APPROXIMATELY

AND

FLUE DUCTS ARE ACCURATELY CUT TO THE REQUIRED LENGTH

L PLUS

ASSEMBLY

to

STANDARD

51mm

28mm

TWO

3mm

TOGETHER WITH

13

1200mm

100mm

139.4in

to

47.0in)

USE THE

9.1

b BEFORE

(4in) OVERLAP IS

FLUE DUCT /

(2.0in)

J,

(1.1in)----.1

TO

THE ROLLED STOP CHANNEL. USING THE HOLES

DIAMETER HOLES THROUGH THE FLUE

TWO

SELF-TAPPING SCREWS SUPPLIED.

ASSEMBLY

ROLL,ED CHANNEL

STANDARD

STOP

FLUE KIT

FLUE

TERMINAL

Fig. 13 Rear flue application I

FOR

WALL

KIT

AND

THICKNESSES/FLUE LENGTHS FROM

THE EXTENSION FLUE KIT

1201mm

to

2000mm

(47.3in to 78.7in) USE THE

STANDARD

FLUE ·

IMPORTANT:

DO

NOT

OF

REDUCE THE LENGTH

THE EXTENSION AIR DUCT

.1__

60mm

(2.38in) I C : l D I

DIAMETER I

REFER

~---*

t------

f DO

DO

NOT

STANDARD

REDUCE LENGTH OF

FLUE DUCT

TO INSTRUCTIONS IN SECTION 9.1e BEFORE CUTTING AIR

Air duct - Rear flue application

ON FINAL

SMEAR OF SILICONE AROUND STANDARD

ASSEMBLY

THE OUTSIDE OF THE

DUCT

APPLY A SEALANT

REDUCE AIR DUCT BY CUTTING FROM END

WITHOUT

Flue duct - Rear flue application

OVERALL

1

265mm

LENGTH~

(50in) J I

L PLUS

51mm

(2.0in)-----,

i'

NOT

EXPANDED

CUT

-----------

END CUTTING SURPLUS

ON FINAL SMEAR AROUND THE

STANDARD

ASSEMBLY

OF

SILICONE

THE OUTSIDE

APPLY A

SEALANT

OF

DUCT.

OR

FLUE DUCTS.

EXISTING HOLES TERMINAL

LENGTH

OF

HOLES

FIEDUCE LENGTH OF

\ EXTENSION

FROM THIS ENSURE END

IS

FREE

FOR

STANDARD

SQUARE

OF BURRS.

FIXING

PIECE

END. AND

BY

NOTE: USE SUPPORT SPIDER

Fig. 14 Rear flue duct assembly

FOR

WALL

1201mm

STANDARD

STANDARD FLUE DUCT

THICKNESSES/FLUE LENGTHS FROM

to

2000mm

FLUE KIT

(47.3in to 78.7in) USE THE

AND

THE EXTENTION FLUE KIT

IMPORTANT:

ON FINAL SUPPORT SPIDER AND

PUSHED

AIR DUCT EXTENSION

* OVERALL LENGTH

23mm

,._

(0.9in)

THE FLUE

SLIDE

OF AIR DUCT

END THE

ASSEMBLY

--

l

TERMINAL

TOGETHER WITH

* OVERALL

AS

INTO THE AIR DUCT UP TO THE ROLLED STOP CHANNEL.

A GUIDE DRILL THROUGH THE FLUE

AS

SHOWN

REFER

TO INSTRUCTIONS IN SECTION 9.1c BEFORE

ASSEMBLY

AGAINST

ENSURE

IS

FITTED OVER FLUE

SUPPORT

THAT

EXPANDED END.

SPIDER~

DUCT

STANDARD AIR

'

L PLUS

LENGTH~

TWO

SELF-TAPPING SCREWS.

FLUE

EXTENSION

L PLUS

51

mm

(2.0in) C : I

DUC/

28mm

(1

1m)

TERMINAL

WITH THE

BELOW

ASSEMBLY

A

FLUE APPROXIMATELY OVERLAP

PROVIDING THE AIR ARE ACCURATELY CUT REQUIRED LENGTH.

DUCT

IS

I

D+CT

'f

~IU!~o'='U'

~"'~\;;;3""18""

ROLLED STOP

CHANNEL

---•

USING

3mm

DRILL SUPPLIED. SECURE

EXPANSION

100mm

ALLOWED

FOR

AND

FLUE DUCTS

TO

A'IJI

AOL_,

og.,o~i(.

THE HOLES IN THE

JOINT

(4in)

OF

THE

FLUE TERMINAL

14

4.

Remove

gasket

press

back Apply a bead the

appliance

standing

Position

of

the and socket. tighten the

flue

rear

the

provided.

the

panel

flue

the

wall

push

Working

the

duct

air

duct

backing

adhesive

around

of

duct

into

centrally

back

face. Pass

the

end

rear

is

socket

paper

Position

backed

the

rear

silicone

and

air

position,

in

front

panel

the

fully

home

through

flue

duct

positioned

and

the

from

the

gasket

side

flue

outlet.

sealant

duct

square

of

the

about

40mm

flue

duct

into

the top

clamping

concentrically

hole

the

square

as

firmly

(Fig. 8). around sockets.

to

the

hole

(1.6in)

through

the

air

screw.

in

the

shown,

against

the

Move

in

rear

duct

wall.

sealing

inside

wall

the

in

the

flue

socket Make within

then

the

of

the face, wall. front

wall

duct sure

the

Fig. 15

MAKE

GOOD

EXTERNAL

Arrangement Standard

WALL

flue

FACE.

of

rear

flue

application

kit

APPLY SILICONE TO

INSIDE OF APPLIANCE

AIR

DUCT

BEFORE INSERTING AIR

INLET

SEALANT

SOCKET

DUCT

5. RECHECK REQUIRED HAVE BEEN

6.

Working assembly about of

flue

over

provided accurately.

7.

Move duct socket.

the

8.

Run a the pushing air

duct

Fig. 16

MAKE WALL

~:~~;;;,

THAT

ANY

STUB

PIPE

CONNECTIONS

(SECTION 9.3).

air

duct

and

expansion

for.

The

will

should

around

home.

flue

MAKE

AROUND

short

engage

to

have

position.

into

the

be

clamping

the

blanking

Tighten

application.

and

extension

GOOD

and

the

been

flush

screw.

AIR

APPLY SILICONE TO INSIDE OF APPLIANCE AIR BEFORE INSERTING AIR

terminal

joint

of

section

push

boiler,

cut

The

air

duct with

inside

of

plate

the

top

INTERNAL

DUCT

SEE DETAIL

FIG. 16

SEE AIR DUCT, FIXING DETAIL

flue.

WALL

IF NECESSARY

INLET

FACE

SEALANT

SOCKET

---

MINIMUM--

FLUE LENGTH

100mm

MAXIMUM FLUE LENGTH 1000mm

FIG. 10 FOR

FLUE

DUCT

L·

(4in)

(39in)

DUCT

SEE FIG. 12 FLUE

DUCT

FLUE

DUCT

HOUSING

APPLIANCE

AND

14

FIXING DETAIL

FOR AIR

DUCT,

from

through

100mm

duct

inside

the

section

the

appliance

should

wall

top

be

The

back

face.

bead

air

it

down

clamping

Arrangement Standard

GOOD

EXTERNAL

FACE

outside (4in) is

of

air

pushed

of

Tighten

of

silicone

duct

until

MADE.

pass

the the

flue and

socket.

screw.

flue

the hole. A flue allowed terminal

duct

connected

flue

ducts

into

its

final

fully

the

it

home

socket

air

duct

sealant

Refit

is

fully

REFER TO SECTION 9.3.

of

rear

assembly

~==od'---n

DO

I

l

FLUE TERMINAL

NOTE:

STANDARD MINIMUM 1000mm

INCREASES

u

J

LROLLD

CLEAR OF

* L

~

FROM

LENGTH

(39in)

FLUE KIT

WITH

TO A MAXIMUM

CHANNEL

WALL.

WALL

THICKNESS

INTERNAL

100mm

(4in).

EXTENSION

TO

BE

WALL

AS

SUPPLIED.

MAXIMUM

FLUE KIT

OF

2000mm

10mm

DISTANCE

TO

EXTERNAL

(78in).

(0.4in)

15

LENGTH

WALL.

FLUE

DUCT

HOUSING

APPLIANCE

9.2

1. Refer

2.

3.

4.

VERTICAL

to

of

Connection Determine

and the page 1 and

125mm Offer possible fixing screws or

the

may screws. A minimum red. Leave Seal

the screwing

Determine duct

H =

of top erter The than roof NOTE: (10in) flue liance 1980mm overall in

When

up be

Determine appropriate flue

Fig 3

Section

mark

centre

{5in)

up

the

to

hole

provided,

into

reinforcement

joists.

be

fixed

any

ceiling

the

required.

the

vertical

the

air

of

the

(Fig 17).

bottom

250mm

space

When

above

kit

will

under

thickness

the

roof

an

to a nominal

used

(Fig 17).

boiler

and

2 -

Siting

of

primary

the

FINAL

on

the

ceiling,

of

the

Fig 4

for

diameter

ceiling

drill

through

positions

fixed

Refer

to

the

plate

loose

air

gap

between

with

silicone

plate

in

the

overall

distance

duct

socket

air

duct

socket

of

the

(lOin)

insulation

the

minimum

joists

accommodate

ceilings

(78in)

and

of

space

is

extension

maximum

the

vertical

section

assembly

FLUE

take

account

the

Appliance,

and

installed

directly

vertical

dimensional

accurately

plate,

and

the

for

the

either

nags,

Fig. 19.

ceiling

of

four

for

now.

final

position.

length H of

measured

on

top

on

diverter

above

installed

is

used

the

of

2424mm

joists,

150mm

duct

kit is

flue

below,

procedure.

SYSTEMS

of

the

secondary

air

using

fixing

the

sealant

the

must the

diverter

the

nominal

plaster

(5.9in), Fig 17.

of

length H by

which

and

vertical

position

above

duct

socket. Refer

details.

through

position

plate

and

No. 8 x

into

the

which

may

Alternatively,

plasterboard

positions

back

of

applied

vertical

from

of

the

appliance

underside

be

situated

ceiling

on

top

of

height

STANDARD

installation

height

(95.4in)

and

used,

3424mm

details

requirements

Section

flues.

of

the

appliance,

Cut a hole

the

ceiling.

it so

that

provide

30mm

existing

be

fixed

the

toggle

is

the

plate

prior

primary

the

bottom

to

of

the

no

joists

or

the

joists.

of

250mm

vertical

of

the between

when

any

insulation

ceiling

(134.8in)

refering

the

heights

to

correct

18 -

boiler

to

it is

four

wood

joists

to

plate

requi~

and

to

air

the

div-

less

any

app-

the

may

the

(d)

Reduce duct

(e)

Using 'A' the a previously and

Fig.

ROOF SPACE

JOISTS, INSULATION,

1

156m""""ill

(6.0in)

··-~

OVERALL VERTICAL FLUE LENGTH

1557mm-2000mm (61.3in-78.7in)

WITH

FLUE KIT

2001mm-3000mm

WITH EXTENSION

the

'8'

to

the

two

as a

guide,

drill

supplied.

smear

of

silicone

inserted

secure

with

17

PLASTER,

I--~=~

STANDARD

(78.8in-118.1in)

FLUE KIT

H

length

ETC.

of

required

holes

drill

two

Disengage

sealant

end

two

self-tapping

MAX.

the

duct

overall

in

the

expanded

3mm

the

around

of

air

SECONDARY FLUE DIAMETER

NOMINAL

HEIGHTS

1980mm-2424mm

(78in-95in) STANDARD FLUE KIT.

3424mm

MAX.

EXTENSION

'!"

FLUE KIT

I I I I

I I

with

length.

diameter

air

ducts

the

duct

'8'.

screws

125mm

t

CEILING

(134.8in)

WITH

plain

end

of

holes

and

outside

Reassemble

supplied.

(5in)

USING

ends, ail'

air

duct

usinq

appl~·

of

the1

Section

9.2a

9.2b

9.2a

BOILER VERTICAL

(

1557mm-2000mm)

For

overall

(61.3in-78.7in) use

1.

Cut

(a)

The overall

quired.

(b) Do (c)

Fully ded

and

overall

not

engage

end

flue

assemble

length

reduce

of

air

Overall

FLUE

height H between

the

standard

the

H. (Figs 17

of

110mm

the

length

one

end

duct

'A'.

length

flue

duct/air

557mm-2000mm

1

(61.3in-78.7i

2001

mm-3000mm

(78.8in-118.1 in I

ASSEMBL

(61.3in-78.7in)

flue

air

duct

(4.3m)

of

air

of

air

duct

of

vertical

duct

H

n)

1587mm-2000mm

kit

only.

as

follows

and

20).

diameter

duct

'A'

(Fig. 20).

'B'

into

V -

(Fig 20):

This

is

air

duct

the

expan-

the

re-

2.

Cut

and

(a)

Fully panded

(b) Reduce

the

air

60mm

(c)

Do

not

(d) Reduce

plain

(e)

Using 'E'

as a

the

drill

Engage ded

end holes meter two

ducts.

Apply a smear of

the expanded self-tapping

assemble

engage

end the

ducts.

(2.38in)

reduce

the

end

only

the

two

guide,

supplied.

one

of

in

the

holes

plain

end

the

of

flue

length

(Fig. 20).

diameter

the

length

(Fig 20).

holes

drill

end flue

socket

using

of

end

of

screws

the

flue

plain

end

duct

to

length of

flue

in

the

two

Disengage

of

the

flue

duct

at

end

as a

the

drill

silicone

of

flue

duct

provided

duct

of

flue

'E'

(Fig 20).

the

This

flue

duct

of

flue

duct

expanded

3mm

thH

stub

'D'

(Fig 20).

guide,

supplied.

sealant

duct

'E'

(Fig 20).

l

as

follows:

duct

same

length H used

is

the

required.

duct

'E'

by

diameter

ducts.

duct

drill

around

'D'.

Engage

and

'D'

into

overall

fix

length

'D'. (Fig. 20).

cutting

from

end

of

flue

holes

into

the

Using

two

3mm

Disengage

the

it

with

the

outside

the

ex-

for

the

duct

using

expan-

two dia-

the

two

of

16

Fig. 18

Top

Stub

- Rear

Flue

View

AIR DUCT CLAMPING SCREW

*FLUE

DUCT CLAMPING SCREW

SEE

NOTE~ /

mnO"""

FLUE DUCT

* NOTE:

Access

to

the

flue

a

hole

in

the

3.

{a)

Apply

a bead

the

top duct Working panel clamping

Ensure

within

flue

without

through

of

the

screw.

the

air

REPLACE THE ACCESS COVER.

(b)

Partly

assemble

Slide

the

be

inserted

inside

the

before

the

way

duct

in

the

support

duct

the

sealing

the

to down duct correct of socket wards.

Slide duct Ensure

DOWN.

(c)

Before

positioning assembly assembly bottom den long, is

vertical.

(d) Refer

Lift ing

(e)

Lift ficient it

and

9.2a.4.

batten

off

to

the and

the

to

the

through

far

of

the

Fig 19.

sealing

fix AIR

allow

flue

duct

upper

front

of

silicone

outlet

socket.

holes

the

casing,

(Figs 6

stub

duct

socket.

the

spider

into

the

to

the

air

duct.

round.

The

should

centre

of

plate

commencing

socket

the

enough

flue

duct between ground.

plate

as

described

duct

assembly

the

appliance

duct

supported

fully

flue/air

be

on

into

Ensure

up

Duct

Application

TOP OF BOILER

lm

I

NNE/ASING

-~STUB

FLUE DUCT

SEALANT

=SIN~

REAR

FLUE OUTLET WITH BLANKING PLATE IN POSITION

clamping

casing.

sealant

access

tighten

and

is

over

diverter

expanded

air

positioned

the

over

the

boiler,

hole

to

950mm-1

to

under

Insert

into

the

hole

7).

positioned

duct

the

socket

Ensure

duct

flue

duct

the

to

position

sealing

push

in

the

roof

be

supported,

OOOmm

the

underside

Section

into

to as

screw

is

(Fig. 6)

around

the

end

socket.

in

the

top

concentrically

system

end

of (Fig 20). Push

end.

Slide

both

ducts

socket

upwards

positioned

top

end

the

plate

the

top

the

ceiling.

space

supported

9.2.2.

the

roof

be

positioned

described

through

the

inside

of

the

stub

{Fig 18).

upper

front

flue

outlet

as

follows.

the

flue

duct

the

flue

are

in

to

using a woo-

(37.5in-39in)

of

the

centre

and

the

down-

of

the

assembly.

is

looking

of

the

flue

Lift

the

allow

the

assembly

the

ceil-

space

suf-

under

in

Section

air

of

it

Retain

the

AIR

ing

plate

Ensure

4.

(a)

RECHECK TO ENSURE

clamping

the

assembly

duct

NECTIONS REQUIRED HAVE

Refer

to

Move supported flue assembly.

Run a the the

(b)

Lift

wooden

moving the sliding with

(c)

Slacken the socket.

(d)

Working top

(i)

(ii)

(iii)

Section

the

outlet

bead

top

air

flue

stub

the

vertical

batten.

the

outer

the

two

the

outer

within

of

the

Apply a bead side diverter.

Apply a smear side

of

Slide bottom flue

ducts.

appliance

vertical

socket

of

duct

duct.

flue

appliance

air

duct

socket

self-tapping

sealing

air

duct,

flue

system

of

the

flue

the

air

of

the

9.3.

silicone

socket

Support

end

sliding

the

air

duct diverter

5.

(a)

Ensure the system ducts top clamping

Now Section

Fig. 19

DRILL A DIA.

IMPORTANT

Before

plate

of

silicone

ensure

fixing

edges

the

is

are

bottom

Refer

flue

vertical

fully screws.

the

to

appliance

and

install

8.

Sealing

MINIMUM

FOR

No.8

NOTE:

screwing

into

position,

sealant -sufficient

an

air

tight

around

of

the

plate.

system

slightly

home

of

secondary Section

Plate

OF FOUR HOLES

x 30rnrn

the

run a bead

seal

all

four

in

position

screw

is

into

flue.

in

line

system

into

raised,

over

plate

roof

as

of

silicone

duct

of

silicone

duct

to

check

in

the

vertical

9.3.

Fixing

WOOD

sealing

(Fig 19).

vertical.

THAT

BEEN

position,

Position

with

sealant

and

around

assembly

the

assembly

its

lower

the

screws

clamping

the

end

space,

follows:-

socket

at

the

and

flue

over

is

vertical.

achieve

that

their

respective

flue

CLAMPING SCREW

to

after

by

tightening

ANY

STUB

the

PIPE

MADE

just

in

the

around

final

the

flue

provided

into

fit

sealant

at

sealant

top

duct

the

this.

the

ducts,

in

front

centre

supported

the

open

and

remove

by

hand

position.

inner

stub

duct.

(Fig 20).

screw

the

top

the

diverter

around

the

bottom

around

of

the

flue

sockets

end

of

the

If

necessary

When

air

duct

sockets

then

tighten

accordance

6mrn

(0.25in)

of

the

inside

Keeping

flue

and

air

the

system.

the

and

SCREWS

FLUE SEALING PLATE

25mm

MINIMUM

GAP

TO COMBUSTIBLE

MATERIAL

seal-

CON-

of

the

top

flue

of

end

of

the

whilst

duct

Secure

lower

duct

to

the

in-

of

the

out-

at

the

air

and

move

flue flue

at

the the

with

17

Fig.

20 Vertical flue application

FOR

OVERALL VERTICAL FLUE LENGTHS FROM

VERTICAL FLUE KIT IMPORTANT:

AIR

REFER

DUCT·

TO INSTRUCTIONS IN SECTION 9.2a BEFORE CUTTING AIR

VERTICAL FLUE APPLICATION

1557mm

to

2000mm

(61.3in

FLUE

to

78.7in) USE THE

OR

DUCT·

VERTICAL FLUE APPLICATION

FLUE DUCTS

STANDARD

OR

ASSEMBLiNG

TOP

~

B

ALL

OVER

TH

LENG

H

SECTIO

N 9.2(3)

A

L__~

ri

110mm

A FLUE DUCT EXPANSION

OF

APPROXIMATELY

OVERLAP PROVIDING THE AIR DUCTS ARE ACCURATELY CUT

TO

IS

THE REQUIRED LENGTH

SEALING PLATE

(4.7in)

DIAMETER

100mm

ALLOWED

AND

CONNECT TO DIVERTER

AIR DUCT SOCKET

/

REDUCE LENGTH

ECTION

-

t-

s

FROM THIS

ENSURE ENDS ARE SQUARE CUT

AND

ON FINAL

SMEAR OF SILICONE

A

ROUND THE OUTSIDE OF THIS

A

s ECTION

LF·TAPPING SCREWS PROVIDED

SE

DO

t-

OUTLET SOCKET

DIVERTER

JOINT

(4in)

FOR

FLUE--

NOT

THIS

JOINT

SECURED

F

LUE

ASSEMBLY

ARE

IN THEIR

REFER

CONNECT TO APPLIANCE AIR

DUCT INLET SOCKET

FLUE STUB

OF

SECONDARY FLUE SYSTEM

CONNECT

FLUE

DUCT

OF

BY CUTTING SURPLUS

FREE

FROM BURRS.

ASSEMBLY

THIS

END.

APPLY

SEALANT~~~~J/......~\

AND

FIX

USING

CUT THIS SECTION

IS

NOT

UNTIL

AND

FINAL

SECTION 9.2a.(4)

DUCT~

125mm

TO

(5in) FLUE

FOR

BS

5440-1

TOP

oono

TWO

SEALED

THE

MAIN

APPLIANCE

POSITIONS

CONNECTION

r!~;;~C

;

TO

DIVERTER

SOCKET

~-------

------11

OR

SCREW

LA~MPING

2

--18mm APPLY A BEAD

SOCKET

E

OVERALL

LENGTH

SECTION 9.2(3)

D

CLAMPING

CONNECT STUB

FLUE SOCKET

ON TOP OF FLUE HOUSING APPLIANCE

DEEP DIVERTER

AIR DUCT SOCKET

SEALANT

ON

OF

INSIDE THE

FINAL

ASSEMBLY

H

SCREW.

BEFORE

INTO

SILICONE

DUCT

TO

OUTLET

DUCT

MOVING

POSITION

ON FINAL

THAT

OVER

AGAINST

SELF TAPPING

BOTH SOCKETS REQUIRE

BEAD

OF

SILICONE

AROUND

FINAL

ASSEMBLY

SUPPORT SPIDER IS FITTED

FLUE DUCT

EXPANDED END

DUCT--·-·-------~

FLUE

AIR DUCT

FIX WITH

(PROVIDED)

SEALANT

THE INSIDE

ASSEMBLY

ENSURE

AND

PUSHED

-----------;:.11

SCREWS~

A}

AIR DUCT

SOCKET

ON

FLUE

SOCKET

---------Jl'll

~

DUCT-

II

[}-

18

!

OVERALL

LENGTH

H

-INSTALLING

NOTE: H ~THE VERTICAL DISTANCE

MEASURED FROM

AIR DUCT INLET SOCKET

APPLIANCE

SELF-TAPPING SCREWS

CONNECT STUB DUCT TO

APPLIANCE

HOUSING

APPLIANCE INTO POSITION

THE BOTTOM

TO

THE BOTTOM OF THE

DIVERTER.

(PROVIDED)

FLUE DUCT

BEFORE

VERTICAL FLUE

SEE

FIG. 18

ON

MOVING

ASSEMBLY

OF

THE

AND

THE

9.2b

BOILER FLUE

ASSEMBLY

VERTICAL

2001~3000mm

For

overall (78.8in extension

IMPORTANT

ance be

necessary and the

expanded

socket See

1.

Overall

and

floor

'C',

and

(Fig 19).

Section

flue

118.1in)

flue

NOTE:

level

the

9.2b.1 -

flue

lengths

kit

is

to

flue

end

lengths

only.

reduce

99in).

These

flue height the

Cut

(a)

as Determine

22. diameter

(b)

Measure level

Fig.

diverter the

follows:-

This

21a

lengths

between

is

air

ducts

the

is

air

duct

the

(Fig 21a).

the

ceiling

SECONDARY FLUE

125mm

DIAMETER

ROOF SPACE

SUBTRACT THE FROM FOR IF

'X' ~ 2280mm

SUBTRACT 1140mm 1468mm LEAVING

HALF

DISTANCE

1468mm

EXAMPLE:-

HALF OF (45in) FROM (57.8in)

328mm

'X'mm (57.8inl

(12.8in) THIS

IS

AMOUNT

THE CORRECT

TO

CUT FROM

THE PLAIN ENDS

THE AIR DUCTS

OF 'A'

AND

'C'

AND

FLUE

To

determine

'C'

and

TANCE

DUCTS

flue

'X'

'D'

the

ducts

FROM

SURPLUS FROM THE PLAIN END

Proceed

2.

to

Overall

Section

flue

(99.1-118.1in).

{78.8in-118.1

between

use

the

standard

Where

the ducts air

duct

the

2935mm

lengths

'D'

and

'C'

proceed

below

of

otherwise

between

correspond

(2416-2934mm)

fitted

as

shown

'A'

and

'C'

overall

length

overall

required.

height

length

(5in)

lin)

(90in)

'X'

ie

THE

AND

'E'

--

APPLIANCE FLOOR

amount

'D'

and

1468mm

9.2b.2a. lengths

to

be

'E' SUBTRACT HALF THE DIS-

(57.8in) (Fig 21a), CUT THE

between

in)

2001

mm

and

flue

kit

ceiling

height

(83in),

nominal,

of

the

to

air

21b)

sealing

Section

'E' (Fig

fouling

(2001-2519)mm

to a nominal

(95-115.5in)

in

Fig 17.

and

flue

ducts

'H',

Figs

17, 21a, 21b,

of

110mm

'x'

from

appliance

140

250 (10in)

SEALING PLATE

CEILING HEIGHT 'X'

FROM APPLIANCE

FLOOR

=

=-

cut

LEVEL

from

air

OF

THE DUCTS.

ducts

(2520-3000mm)

-

3000mm

plus

from

ducts

to

'D'

(6in)

ONE

appli-

it

will

avoid

plate

9.2b.2.

(78.8-

ceiling

when

and

'E'

(4.3in)

floor

'X'

'A'

and

'A'

(a)

Determine This air

duct

(b)

Assemble the

holes ment

Using socket through age sealant ducts. screws

3.

Cut

and

(a)

Reduce i.e. H (Fig (2.4in)

(b)

Assemble Reduce

(c)

from

(d)

Attach in

each 3mm drill

Disengage spiders

Apply a smear of

the Reassemble

the

self

the

is

the

overall

required.

the

length

of

until

the

with

the

two

ends

the

air

around

Reassemble

provided. assemble

the

21

diameter

the

plain

the

stub

of

the

diameter

provided.

the

(Fig 22).

plain

tapping

overall

air

duct

required

other

holes

as a

ducts,

ducts

the

flue

).

flue

length

end.

three

of

ends

the

length

ducts

'B'

two

guide,

using

and

outside

and

the

length This flue

duct

ducts

of

duct,

socket

holes

flue

silicone

of

the

flue

ducts

screws

4.

(a)

Apply a bead the duct through the

screw.

(b)

Partly (Fig 22). positioned

3.c

below

the

flue should Slide duct, assembly. looking

(c)

Before assembly assembly bottom den long, is

vertical.

(d)

Refer side

top

without

casing,

the

batten

off

to

of

flue

outlet

holes

the

access

tighten

(Figs 6

and

assemble

Slide

the

vertically

the

air

duct

sockets

be

positioned

sealing

before

Ensure

down.

positioning

through

far

enough

of

the

flue

between

the

ground.

Fig 19.

the

ceiling

silicone

socket.

fully

hole

7). REPLACE THE ACCESS COVER.

the

flue

duct

plate

commencing

the

duct

Lift

the

and

9.2.2.

(e)

Lift

the

air

duct ficient it

and

to

the

allow

flue

assembly

the

duct

appliance

supported

9.2b.4.

Retain

the

air

duct

in

screw

is

5.

ing

plate

Ensure

clamping

the

assembly

(a) RECHECK TO ENSURE

NECTIONS REQUIRED

9.3).

Move

the supported flue

outlet

assembly. Run a bead

the

top

flue

air stub

the

appliance

vertical

socket

of

duct

duct.

into

flue.

in

silicone

socket

lengths

as

by

overall

pre

drill

secure

flue

to

is

the

'D'

the

using

through

ducts

flue

provided

the

duct

for

sockets

downward.

above

over

socket

boiler,

hole

into

to

950mm-1000mm

Ensure

sealing

fix

position

vertical.

THAT

H.

of

110mm

shown

cutting

length,

ducts

is

obtained

drilled

in

two

3mm

the

drill

apply a smear

of

the with

duct

as

that

used

overall

required.

and

'E'

flue

duct

the

two

ends

as a

the

and

fit

sealant

ducts

D, E and F and

(Fig

sealant

in

fitment

Insert

into

the

top

flue

air

duct

inside

should

the

to on

push

in

the

roof

be

supported, the

plate

as

described

into

to as

by

(Fig 19).

around

the

upper

as

The

the

supported

the

be described

ANY

HAVE BEEN

position,

Position

line

sealant

and

the

with

around

Figs

17, 21b, 22.

(4.3in)

in

Fib

from

the

after

each

diameter

provided.

plain

four

follows:-

for

the

length

and

'F'

only

holes

guide,

ducts,

the

two

around 'E'

and

21

).

the

end

socket.

front

outlet

system

the

air

described

be

support

flue

duct

top

end

position

the

sealing

the top

ceiling.

space

using a woo-

up

to

under

roof

positioned

tightening

STUB

MADE

just

in

centre

the

supported

the

open

diameter

21b. ReducH

end

with

engage-

(Fig

21

b).

of

the

three

holes

Diseng-

of

silicone

ends

of

self

the

'F'.

secure

of

duct.

upward

to (37.5in-39in)

space,

PIPE

the

tapping

air

ducts

of

60mm

{Fig 21b).

by

cutting

pre

drilled

drill

two

using

the

support

outside

with

inside

the

stub Working panel

clamping

as

follows

When under

and

spiders

sockets.

of

the

flue

plate

of

the

flue

Lift

the

allow

the

assembly

the

under

Section

suf

under

in

Section

the

seal·

CON

of

air

is

(Section

front

of

the

of

the

top

flue

inside

of

end

of

19

(b)

(c)

(d)

Fig.

Lift

the

wooden

moving

the

outer

sliding

the

with

the

Slacken the

outer

socket.

Working top

of

the

(i)

Apply a bead side diverter.

21

Vertical

vertical

FOR VERTICAL

IMPORTANT·

flue

batten.

the

appliance

air

socket

two

the

sealing

air

within

flue

of

the

system

Support

duct

raised,

end

self-tapping

duct

sliding

the

system

of

air

duct

flue

OVERALL VERTICAL FLUE LENGTHS FROM

AND

REFER

DUCT-

AIR

VERTICAL

assembly

the

assembly

into

its

final

over

plate

roof

as

silicone

lower

the

screws

clamping

the

space follows:-

socket

flue

provided

end

fit

sealant

at

position.

the

stub

screw

into

the

application

EXTENSION FLUE KITS.

TO INSTRUCTIONS IN SECTION 9.2b BEFORE CUTTING AIR

FLUE

APPLICATION

and

remove

by

hand

inner

duct.

(Fig 22).

the

top

diverter

around

bottom

REFER

Keeping

flue

Secure

and

air

the

2001mm

TO FIG.

the

whilst

duct

lower

duct

to

the

in-

of

the

22

to

3000mm

(ii)

(iii)

6.

(a)

{78.8in

FLUE

Apply a smear side

diverter. Slide

bottom

flue

ducts.

Ensure the system ducts top clamping

Now Section

the

appliance

is

are

and

bottom

instal

8.

to

118.81nl USE THE

OR

DUCT·

VERTICAL FLUE APPLICATION

of

the

air

of

the

flue

slightly

vertical

fully

home

screws.

the

Refer

FLUE DUCTS

of

silicone

air

duct

and

diverter

system

to

check

in

their

of

the

vertical

secondary

to

Section

STANDARD

OR

sealant

socket

at

flue

over

the

is

vertical.

achieve

that

the

respective

ducts,

flue

9.3.

ASSEMBLING

around

the

bottom

duct

sockets

end

If

necessary

this.

When

air

duct

then

in

accordance

of

the

and

sockets

tighten

the

of

at

air

move

at

with

in-

the

and

flue flue

the the

OVERAL

SEES

9.

L LENGTH H ECTION 2(3)

1

TOP

'

1--··---------

8

~

11'

c

~s

jJ

-

A

CONNECT TO OIVERTER

FLUE SOCKET

CONNECT TO DIVERTER

AIR SOCKET

LENGTH

REDUCE

ISS

SE

-

SE AS

SE

TH

BY

CTION

ROM THIS

F

QUARE

ON

A

SMEAR

A

ROUND THE OUTSIDE

ECTION

s

LF-TAPPING SCREWS PROV

DO

UNLESS SPECIFIED

ON FINAL ASSEMBLY APPL

MEAR

AROUND

T

HIS SECTION

TWO

DO

UNLESS SPECIFIED

IS

CURED UNTIL THE

SEMBL Y

I

N

REFER

CUTTING SURP END. ENSURE E

AND

FREE

FINAL ASSEMBLY APP

OF

SILICONE SEAL

AND

FIX USING

NOT

CUT THIS SECTIO

SECTION 3.2b

OF

SILICONE SEALA THE OUTSIDE 0

SELF-TAPPING SCREW

NOT

JOINT

THEIR FINAL POSITIONS

AND

PROVIDED

CUT THIS SECTIO

SECTION 9.2b

IS

NOT SEALED

AND

APPLIANCE A

SECTION 9.2b(41

OF

THIS

FROM 8

OF

UNDE

FIX USI

UNDE

MAIN

............

------~-----------...

TOP

~

LUS

TW

FL

NO

URRS

LY-

ANT

HIS

T

IDEO

N-

R

YA-_

NT

F

NG

s

N

R

OR

UE

RE

0

1

-

r-

F

E

D

OVERALL

SEE

s~1~;l

9

H

I_

TION

ENGTH

1--J

110mm

(4.3in)

DIAMETER

NOTE: H

=The

on

v

OUTLET ON TOP

vertical distance

the

appliance

CONNECT TO AIR DUCT INLET SOCKET

FLUE STUB

CLAMPING

CONNECT TO FLUE SOCKE

HOUSING BEFORE APPLIANCE INTO POSITIO

measured

to

the

APPLIANC~

DUCT·~--

SCREW-_

OF

FLUE D

MOVIN

from

the

bottom

of

the

diverter

20

~

'~

-~~

T

UCT

G

N

I

of

the

air

duct

:--

inlet

-

::a

I

socket

Fig. 22 Vertical flue assembly

IMPORTANT:

REFER REFER

TO

INSTRUCTIONS IN SECTION

ALSO TO FIG.

DIVERTER

28

9.2b

BEFORE CUTTING AIR FLUE DUCTS

125mm

SOCKET

SECONDARY

(5in) FLUE OUTLET

FOR

CONNECTION OF

FLUE SYSTEM

BS 5440.1.

TOP

DODD

DODD DODD

----~DODD

DODD DODD

TO

OR

CLAMPING

ASSEMBLING.

SCREW

A FLUE OF APPROXIMATELY

PROVIDING THE AIR

ARE

ON

FINAL

ENSURE SUPPORT SPIDERS ARE FITTED OVER

FLUE DUCT

PUSHED

EXPANDED END

DUCT

OVERLAP IS

CUT

ACCURATELY TO THE

REQUIRED LENGTH /

FLUE SEALING

ASSEMBLY

THAT

AND

AGAINST

SELF-TAPPING

SCREWS PROVIDED

EXPANSION

100mm

ALLOWED

AND

FLUE DUCTS

PLATE/

JOINT

(4in)

FOR

/"///

TAPPING

SCREWS

PROVIDED

SELF-

_____

JlJllr----,11

OVERALL

LENGTH

H

18mm

DEEP DIVERTER

AIR DUCT SOCKET.

SILICONE

INSIDE THE SOCKET

ON

APPLY

FINAL

A BEAD OF

SEALANT

ASSEMBLY

FIX WITH

SELF-TAPPING SCREWS......._

(PROVIDED)

BOTH SOCKETS REQUIRE A }

BEAD

OF

AROUND

SILICONE

THE INSIDE ON FINAL

ASSEMBLY

SEALANT

AIR OUCT

FLUE

--.

----!1

DUCT---~~

-......._~

....

~~gK~~T

FLUE DUCT

SOCKET

-~-..r.::::=:!is;t..,

21

··-<>

NOTE:

H =

The

vertical distance

from

STUB

SEE

the bottom

DUCT

MOVING AND

INSTALLING

ASSEMBLY

FIG. 18

APPLIANCE

measured

air duct to the bottom of the socket under the diverter.

HOUSING

INTO

inlet socket on the appliance

CONNECT

APPLIANCE FLUE DUCT

BEFORE

POSITION

VERTICAL FLUE

of

TO

the

9.3

All

Refer

It is

obstruct

COMPLETION INSTALLATION PRE-PLUMBING

installations.

to

Figs

1,

2,

3,

4,

5.

most

important the pipework is routed so as not to

access

to the circulating

OF

APPLIANCE

AND/OR

OF

APPLIANCE

Remove all plastic caps.

pump,

dhw

filter

regulator.

1.

Check

that

the

2.

firm

and

quired. Prepare

level.

the

connections

proposed

No

special

position

floor

working

of

the

protection

from

the

out.

(a)

Remove

disconnecting

valve

the

union

central

the

and

tee

at

heating

at

the

entry

flow

tee

smaller

to

the

connection

pump

heat

bank

47).

(b)

Remove

connecting

the

central

the

top

heating

union

above

return

the

pipe

diverter

(Fig 45).

Remove

with

the

safety

primary

valve)

expansion

by

disconnecting

feed

pipe the

(complete

union

47).

(c)

Make

any

required

(d)

Sealed copper).

sion

(e)

Remove

from

expose Cistern

Prise card

(f) Fit

ELBOW Replace

washer.

(g)

Attach a capillary flow

(h)

Attach a capillary

(j)

Attach a capillary loose direction

Refit valve.

(k)

Sealed Systems Only:

the tundish pipe.

(On removed and the connection capped).

Refit the

Tighten any unions.

(I)

Safety Valve Discharge Pipe: The discharge pipe lrom

the tundish must be continued in 22

laid

discharge

in

The

not

The

in a location

Discharges wire cage or similar is positioned to prevent contact, while maintaining visibility.

IMPORTANT: checked appliance servicing Note:

TWELVE

Systems

loose

pipe,

combined

(On

or

capillary

direction

the

hot

the feed

out

the

plastic

it.

the

Rc%

SUPPLIED

the

pipe

(22mm

loose

central

left.

Refit

the

central

up

the

pipe,

open

vent

22mm

to a continuous

200

The

water

will be satisfactory.

pipework should have a resistance to flow of water

greater

than that of a straight pipe 9 metres long.

termination of the discharge pipe must be visible,

not

at

The

during

and

any

of

the

appliance.

period

MONTHS.

alteration

Only:

feed/expansion

open

vent

elbow

up).

union

(complete

water

cold

flow

hot

water

regulator

(%in

BSP) x

to

the

union.

or

compression

copper),

or heating tee.

or

low

operation

between

flow

or

heating

to

the

left.

including

systems

primary expansion/feed pipe.

fall

within the pipework. A fall in excess of 1

readily accessible to persons.

level are

the

initial

subsequent

to

Cap

off

systems

to

the

with

inlet

of

regulator.

supply

systems

from

the

15mm

dhw

cold

Do

not

direction

compression

tee,

compression

return

the

washer

Fit

a 22mm pipe

the

safety

to

avoid

acceptable

of

the

commissioning

services

the

gas

supply

the

open

end

pipe

attach a compres-

loose

feed/expansion

filter

the

omit

direction

pipe

safety

should

and

boiler.

only:-

inlet

pipe

COMPRESSION

inlet,

direction

the

filter

elbow

to

up.

elbow

up

elbow

(28mm

at

the

to

the outlet lrom

valve

mm

copper pipe, and

the

retention

providing

valve

NOT

should

MUST

following

or

flow

boiler

is re-

centre

isolation

(Fig

by

dis-

valve

(Fig

pipe.

of

the

(22mm

gasket)

This

will

and

dis-

up.

and

the

dhw

to

the

or

to

the

to

the

copper)

diverter

of

any

that

of

the

EXCEED

is

by

be

but

be

3.

Depending

ted, stallation ance

Connect

4. viously

the

with

5.

Thoroughly cold

6.

Connect appliance. for

7.

Connect Electrical. refer

Reassemble

8.

front has

9.

For

Make The terminal from

If

necessary,

Section

gas

water

taken horizontal

inside

on

horizontal

and

Section

the

gas

the

connection

pipe

cock

either

with

under 2 above.

service

BS 6891: 1988.

the

soundness.

the

also

cover

good

will

the

wall.

6.5-

flush

water

Fill

the

mains

For

frost

to

Section

the

until

the

place.

flue

the

external

edge

of

protrude

fit a terminal

HORIZONTAL

water.

particular

or

vertical,

9.1

the

system

appliance

systems.

to

and

9.2.

to

the

Check

for

gas

whole

system

venting

lead

as

and

room

13.

commissioning

brickwork

the

rolled

approximately

guard

type

complete

the

appliance

gas

inlet

the

gas

soundness

of

the

pipes

described

thermostat

leaving

channel

as

FLUE

TERMINAL

of

flue

connection

pipework

in

water

at

the

as

required.

in

off

(see

or

wall

fixed

10mm

specified

system

the

flue

in

accord-

pre-

up

accordanc·e

system

connections

the

rear

of

Check

Section

cabinet

Section

rendering.

to

the

(0.4in)

under

with

th'e

1~:,

14)

flu~~

fitin-

to

POSITION.

10.

SEALED CISTERN

PRIMARY

FEED -

SECONDARY

SYSTEM

See Figs 23

THE QUIREMENTS

The

open

must

1.

For cal

2. THE

The

a

The head appliance vessel with a static

The with a schraider is pressure

and

24.

INSTALLATION

OF BS 6798

end

of

and

the

flow

Fig

be

sizes

Data

sealed.

EXPANSION

expansion

charge

expansion

therefore

of

as

pressure

the

system

to

the

supplied

head

adjustable

gauge,

MUST

combined

and

5.

COMPLY WITH THE

and

BS

5449:1.

feed

and

return

pipework

expansion

refer

VESSEL CHARGE PRESSURE

vessel

is

highest

is

of

vessel

tyre and

charged

must

not

measured

point

therefore

0.5

bar

is

charged

type

valve.

by

should

to

0.5

be

less

than

from

the

of

the

suitable

(17ft).

with

The using a tyre be

charge

increased

system.

air

to

Techni-

bar

the

top

for

systems

and

pressure

pump

if

required.

RE-

pipe

(7 psi).

static

of

the

The

fitted

and

22

Fig. 23b SYSTEM FILLING AND MAKE-UP

HEATING

RETURN

NON RETURN

VALVE HOSE

J----1+-.+-.L.,--M..!.,f

TEST COCK

STOP COCK

HEATING

RETURN

VACUUM BREAKER

!

TEMPORARY

AUTO AIR

VENT

UNION

HOSE

RETURN

VALVE

.t...

NON

t:..::;;::j

WATER

SUPPLY

MAKE

VESSEL

+-

~

STOP COCK

FILL POINT

3.

SYSTEM

A system pany return

A

(a) A

tribution

pressure.

cock

vacuum

(See Fig. 23b).

With pressurisation that as able, ted

FILLING

system

that

and

connection

system

temporary

in

pipe

The

to

BS 1010, a

breaker

this

method,

of

the

supplied).

alternatively a make-up

as

described

AND

should

connected

be

is

acceptable

as

common

hose

or

from a service

connection

and

of

the

expansion

An

increase

below.

connection

water

MAKE-UP

incorporated

to

as

close

possible.

use

is as

should

test

cock, an

an

approved

make-up

system

vessel

to a cold charge

of

0.5 vessel

for

the

to

filling

local

Water

the

central

follows:-

is

made

from a dis-

pipe

under

incorporate a stop

approved

non-return

is

achieved

pressure

pressure,

bar

would

can

be

UP

a sealed

Com-

heating

mains

type

valve

by

pre-

above

(0.5

bar

be

suit-

connec-

(b)

CONNECTION

In

systems

is

equal should highest than 3 litres should as

possible

and

automatic

4.

SYSTEM

The

expansion commodate upon pressurisation ence system ferent

If

it

is that then turn the

total

to

BS 5449:1

NOTE:

If

fitted

to maximum should (primary)

Table

the

be

8

where

to

the

be

used.

point

be

made

and

VOLUME

the

should

volume

conditions

found

catered

an

connection

Initial

pressure-

for

extra

expansion

and

the

pressure

appliance

temperature,

fitted

return

as

Total

System

0.5

1.0

1.5

2.0

DF A

MAKE-UP

the

static

of

(5.3

air

differing

initial

pressure

be

that

vessel

to

initial

head a manually Position the

as

include a non-return

vessel

made

that

with

by

of

BS

the

close

Bar

at

least

system pints) close

vent.

can

the

can

the

vessel

indicated

exceeds

Volume -litres

to

fitted

system

charge

of to be

the

system

the

expansion

be

appliance

6798

an

system

to

the

of

standard

for

and

the

to

the

Table 8 to accommodated

added

volume

2.6bar extra

boiler

VESSEL (See Fig. 24)

system

water.

I

(5.5)

design

1m

(39in)

containing

The

central

valve,

the

appliance

volumes pressure system

expansion

volume

vessel

as

possible

is

further

information.

on

the

when

expansion

in

the

as

possible.

(gallons)

Vessel pressure

0.5 1.0

156

(35)

96 122.5

121

I

51.5

11.51 24 32.5 39.5

pressure

filled

container

above

not

connection

heating

stop

will depending and

if

any.

establish

under

vessel.

is

in

excess

provided,

close

to

the

operating

charge

-

Bar

(27)

(7)

so

system

adE~quate.

pressure

heating

69.5 85

(15.5) (18.5)

the

more

return

cock

ac··

pre-

Refer-

the dif-

of

re-

that

Refer

gauge

on

vessel

1.5

(9)

Fig. 24

NOTE:

LOCKSHIELD RADIATOR

'\~

_..l._

Sealed

Open

A DRAIN COCK FITTED

THE SYSTEM

OF

IIIII~

_____

Primary

Vent

1m MINIMUM

AT

THE LOWEST POINT

Water

Secondary

~~----------

(39in) STOP

111111

SHOULD

II:IIW

_L

_____

System

Water

NON

BE

System

e

RETURN

...L_--1.,~

VALVE!

COCK.

-t

I

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r----2m

I I

I I FIG. 23b

I

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I

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TOP UP BOTTLE MAX

CAPACITY WATER FEED CISTERN

31

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(Section

AUTO AIR

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I.

~

BOILER APPLIANCE I

>-

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PRESSURE GAUGE DRAIN

~

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SPINDLE

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II

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5.

VENTING

The

automatic Fig. 24) cap now filling.

The vents

6.

SYSTEM

(See Table 4).

A flow

heating

A

24. meter

fitted To

on

iator

With

heating imum

across

7.

PUMP

The

be

8.

DOMESTIC

The tinuously

long should HEAD OF

24).

9. PRESSURE RELIEF

A

3bar into a tundish,

discharge pipe should be fitted to the pipe. The point of discharge from the pipe must be visible, and positioned protected occupants and surrounding materials.

is

this

automatically

heating

at all

suitable

rate

output

suitable

The

pipe

with a suitable

adjust central

valves

the

system

amount

the

pump

reduced.

feed

horizontal

be

spring

(451bs.f/in") is fitted within the boiler. It discharges

air

vent

fitted

with a protective

should

BY-PASS

by-pass

aid

from

4.6m

loaded

be

system

high

points.

by-pass

indicated

used

position

should

at

least

the

by-pass,

heating

set

fully

of a contact

and

necessary

flow

and

has

been set at

HOT

WATER COLD FEED CISTERN

pipe

should

the

runs

positioned

(15ft)

pressure

fitted

to

present

fitted

removed

be

vented

should

designed

in

must

for

2m

valve

with

restrict

return

appliance

VALVE

directly

be

Table 4 corresponding

be

the

by-pass

be

connected

(7ft)

to

the

boiler

the

system

open

for

thermometer,

the

to

pipe

MAXIMUM

be

15mm

to

should

to

above

be

provide a MINIMUM

the

relief valve set to operate at

below

the

minimum

to

the

appliance

black

and

from

fitted

to

fitted.

from

provide

at

by-pass

give a temperature

of

the

avoided.

appliance

plastic

discarded,

this

with

give

the

is

shown in

the

appliance

adjustment.

should

by-pass

least

15°(

(27°F).

and

dia.

cistern.

the

safety

hazard

point

manual

22mm

be 45

balance

by

should

rising

The

casing

(See

screw

air

will

during

minimum

to

the

in

Fig. diaand

operated

and

rad-

minutes.

the

min-

rise

not

con-

use

cistern

STATIC

(Fig

valve. A

to

the

air

of

or

11.

OPEN MAINS

VENT

FEED

SYSTEM

(See Fig. 25)

1.

For

sizes

of

cal Data

2. FEED

The

feed meter feed zontal

The

feed

so

that (3ft) highest highest.

3. PRESSURE RELIEF

A

pressure vented ance

4.

FILLING

An

automatic

heat

exchanger plastic necessary within expansion system. manual

5.

SYSTEM (See

A

suitable flow heating tion

for should 2m

(7ft)

valve

flow

and

Fig.

AND

EXPANSION

and

rising

and

runs

above

and

screw

the

Table

rate

to

expansion

continuously

expansion

should

and

expansion

it

provides a minimum

the

point

in

relief

system.

AND

The

air

output the

be

from provide

It

the

tapping

VENTING

air

vent

adjacent

cap. (See Fig.

from

this

appliance

connection

heating

vents

BY-PASS

4)

by-pass

indicated

used,

by-pass

connected

the

PRIMARY

SECONDARY

and

return

5.

be

top the

VALVE

valve

must

point

at

any

designed

in

is

appliance

adjustment.

pipework

CISTERN

pipe

from

cistern.

avoided.

of

heating

blanked

is

fitted

will

or

system

must

in

The

cistern

the

appliance

circuit,

is

not

be

removed

off.

to

the top

to

the

boiler. Remove

24.)

during

be

expelled

dissipated

should

high

point.

Table 4 corresponding

shown

to

be

in

22mm

and

SYSTEM

refer

to

should

static

Air

fitted. A suitable

diameter

the

appliance

use

should

head

whichever

required

from

of

will

filling.

via

into

give

Fig. 25.

fitted

be

22mm

of

long

be arrangHd

of 1 metre

or

above

on

an

the

insulated

the

be released as

Any

other

the

feed

the

rest

be

fitted

the

minimum

The

by-pass

pipe

at

with a suitable

Techni-

dia-

to

the

hol"i-

the

is

the

open

appli-

black

air

and

of

the

with

to

the

posi-

least

Fig. 25a. Sealed Primary Water System

.---------.,

c j llllllll'

I

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I I

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---------------------~

NOTE: A DRAIN

COCK

INSTALLED

POINT

OF

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BENEATH

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SHOULD

AT

THE SYSTEM BOILER.

LOWEST

I I I I I I

LOCKSHIELD VALVE

,II"iiruJL

I

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I

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BE

AND

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RADIATOR VALVE

I

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DOMESTIC

COLD

SHOWER

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TYPE

.,

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WATER

MAIN

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24

Fig. 25b. Open Vented Water System

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TANK

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INSTALLED POINT

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VALVE

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AT

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LOWEST

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COLD

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TYPE

MAIN

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WATER

MINIMUM

(3ft)

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SURFACE

THE

HIGHEST

HEATING

THE

WATER

AND

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-

STATI

OFT

SYST

'-E

'

I I

I

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HEAD

D

FROM

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POINT

EM

TO

VEL

IN

NTANK

IN

THE THE

TO

THE

BE

TOP

FEED

1m

OR

Of

To

adjust

the

central

set

fully

of a contact

and

necessary

flow

and

pump

reduced.

MAINS

6.

12.

on valves aid system amount the

PUMP

The be

DOMESTIC SUPPLY

NOTE:

The

Water

event

should

of

appliance

maximum

following

Company

of

difficulty

expansion

for

mains

be

made

the

The

housing

soldering

recommendations local pliances.

In

the

1.

COLD SUPPLY

There flow ments 600mm should

2.

HOT SUPPLY

The The

through

gall./min.).

NOTE:

regulator during

by-pass,

heating

open

thermometer,

restrict

return

has

been

FEED

instructions

and

be

no

expansion

cold

in

AND

is

fitted

flow

appliance

flow

regulator

operations

the

boiler

the

by-pass

least

45

balance

by-pass

15°C

maximum

should

minutes.

by

(27°F).

with

for

at

the

to

give a temperature

pipes

of

set

at

SECONDARY

HOT

WATER

are

reference

before

please

device water

water

copper

FLOW REGULATING

with a water

of

domestic

is

limited

is

plastic.

should

fitting

contact

capable

unless

are

connection

only.

hot

to

contained

Do

not

on

adjacent

general

be

any

the

of

separate

made.

flow

15

heat

be

operated

and

radiator

With

the

heating

the

minimum

rise

across

and

should

installation

made

to

of

these

manufacturer.

preventing

arrange-

The

to

the

regulator.

water

available

litres/min.

within

the

housing

joints.

the

not

the ap-

the

final

unit

(3.3

flow

3.

TAPS

AND

Hot suitable

4.

SHOWERS (FIXED HEAD TYPE)

No

anti-syphonage

5.

SHOWERS (LOOSE OR FLEXIBLE HEAD TYPE)

If a loose used

head top ted shower syphonage

nection.

6.

BIDETS

The bidet over-rim ded spray necessary.

7. USE IN

If

the hardness inhibitor should The test

Installation requirements valve

VALVES

and

cold

for

operating

head over a bath, cannot

edge

from

supply

and

fall

of

the

being

must

device

of

is

permitted

flushing

unable

attached.

HARD

appliance

exceeds

(available

be

fitted

water

hardness

paper

or

by

should

to

facilitate

taps

and

mixing

at

mains

arrangements

shower

closer

bath

incorporate

hot

type.

to

No

with

the

hose

than

in

order

immersed

at

the

and

cold

provided

The

have

anti-syphonage

WATER AREAS

is

used

in

any

200

ppm a 'Worcester

from

Worcester

into

the

cold

may

be

local

determined

to

strictly

Water

reference

of

the

servicing

pressure.

flexible

must

25mm

that

in

or

be

point

mains that

outlet(s)

any

temporary

area

supply

the

Local

in

Company.

may

valves

are

be

(1.0 in)

the

bath

fitted

of

flexible

water

the

arrangements

where

Heat

to

accordance

be

incorporated.

used

must

be

nE~cessary.

hose

is

to

fixed

so

above

head

is

water,

with

hose

direct

bidet

should

hand

the

temporary

In-Line'

Systems

the

appliance.

using a standard

Water

Company.

An

that

the

preven-

or

the

an

anticon-

to

is

of

the

be

shrou-

held

scale

Ltd.)

with

the

isolatinn

be

are

a

25

13.

In

refer

the

ROOM

If a room

wired

26. from the

ELECTRICAL

order

to

gain

to

Section

appliance

AND

or

into

One

or

the

electrical

hole.

Fig.

26

Room Frost

ROOM THERMOSTAT

CONNECTIONrS---t~

access

3 - Page 4,

top

cover

FROST THERMOSTATS

frost

thermostat

the

appliance

both

of

the

cover

Thermostat

REMOVE

LINK

to

the

Removal

and

facia.

terminal

blanking

and

see

is

plugs

the

Connections

F;gs. 27.

electrical

of

to

be

fitted,

strip

should

cable

and

2a

and

2s

terminal

Cabinet.

as

shown

passed

HONEYWELL ROOM

THERMOSTAT

60606

OR

SIMILAR

it

should

be

removed

strips

Remove

in Fig.

through

be

MAINS

The ilitate via tered ments via a double 3mm controls

Mains

Should then minals side then left two Care place. electrical

gulations,

appliance

WIRING

method

the

a 3

amp

socket

of

in

Cable:

the

marked

of

the

be

hand

cable

should

The

complete

BS 1363.

all

only.

new

passed

side

retaining

external

supply

and

must

of

connection

fused

outlet, pole

poles

0.75mm'

factory

cable

Live,

appliance

through

of

the

be

taken

any be

both

complying

with a contact

supplying

{24 X

mains

should

Neutral

terminal

the

fixed

that

the between

comply

regulations

to

isolation

three-pin

Alternatively

isolator

and

fitted

electrical

clips

wiring

shall

local

earthed.

the

of

the

appliance,

plug

and

connection

the

0.20mm) cable

be

connected

and

Earth at

strip.

cable

clamp

cover

to

the

cable

is

the

with

appliance

unswitched

with

may

separation

boiler

to

BS

need

to

into

the

The

cable

located

and

clipped

left

hand

clipped

appliance

lEE

which

must

fac-

preferably

shut-

the

require-

be

made

and

system

6500 {80°C).

be

replaced

the

ter-

left

hand

should

in

the

into

neatly

and

the

panel.

into

the Re-

The

side

Wiring

apply.

of

FROST THERMOSTAT CONNECTIONS

A

Heyco these at

this

the

cable el. Care neatly

OVERHEAT

THERMOSTAT

MAIN

SUPPLY

.------+-

cord

instructions,

point.

into

OHW

r-::

_,,~---~

licl"'!

I

strain

The

retaining

should

place.

,

:=~~k

be

relief

should

cables

clip

taken

PUMP

bush,

be

should

fixed

14.

COMMISSIONING APPLIANCE

DOUBLE

····~~~~Hz

BOILER

packed

used

to

then

to

the

that

the

bi-~~Ov~

b,-

r-·g/y

POLE

·THERMOSTAT

MAINS

separately

retain

be

clipped

left

hand

cables

p

1101

are

solenoid

r-c-r--'>..'Croi\

FROST

SUPPLY

the

cables

side

clipped

h1

low soiP.rJOid

with

into pan-

Jl<-;c;=

1.

Primary ance through

2.

Gas

including

for

recommendations

When gas

EXTINGUISH ALL NAKED LIGHTS ·

· EQUIPMENT FULLY OPEN

WINDOWS.

Installation:

to

the

primary

with

clean

water.

Installation:

the

soundness

purging

soundness:-

DO

NOT OPERATE MACHINERY

CENTRIFUGAL PRESSURE

FAN

UNIT

The

meter

and

the

purged

of

gas

PIL~

soLErlolf-~:U

THE

Before

whole

shall BS 6891.

connecting

system

pipework

SWITCH IGNITOR

it

of

be

inspected

in

accordance

ALL

the

must

gas

and

DO

OR

be

installation and

checking

NOT SMOKE

ELECTRICAL

DOORS

the

flushed

with

appli-

tested

the

for

AND

~.J~

,

~I

,&,

l.iJ..i.l

j

II

Fig.

27

Wiring

26

PUMP

OVER

TIMER

RUN

Diagram

Fig.

28Functional

240V

~50Hz

FUSE

3A

----

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'

j

.

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3. Check cal

supply knobs system

4.

Open as necessary. matic changer.

10.3

pipework

union

Tighten

that

clockwise controls

all

radiator

air

vent

Refer

and

11.4. Check

and

the

is

gas

off.

The

on

of

air

purging

the

union

service

Turn

to

are

calling

valves

appliance

the

to

Fig. 24

by

until

and

cock is

both

maximum

and

top

and

for

water

loosening

gas

check

off

the

appliance

for

heat.

fill

the

is

fitted

of

the

Fig. 25. soundness.

the

is

smelt.

for

gas

and

thermostat

and

ensure

system,

with

insulated

Also

gas

Refer

the

venting

an

heat

sections

valve

sound-

electri-

the

auto-

ex-

to

5.

NOTE:

at

the

automatically ing

on overheat Press

27

Drain

the

refill

the

and11.4.

burners

the

system

If

the

electrical

isolation

are

circumstances,

thermostat

overheat

heating

switch

firing,

when

system

venting

supply

or a power

the

power

is

it

may

before

thermostat

and

as

detailed

to

boiler

restored.

be

the

boiler

re-set

boiler

the

boiler

failure

will

normally

However,

necessary

will

button

completely

in

Sections

is

interrupted

occurs

depend-

to

re-set

operate.

(Fig 30).

and

10.3

whilst

re-light

the

Fig.

30

OVERHEAT THERMOSTAT RESET BUTTON

I

·~···

DHW HIGH LIMIT THERMOSTAT RESET BUTTON

6.

Switch

electrical

NOTE:

the

ing whether pump the

Fig.

Immediately

boiler

the

pump

or

will

normal

31 a Gas

240v ELECTRICAL

SUPPLY

TO

SOLENOID

supply

the

pump

to

run

not

the subsequently operation

controls

control

PILOT

on

at

mains

electricity

delay

timer

for

about 5 minutes,

are

only

the

boiler.

valve

run

adjustment

of

240v ELECTRICAL

SUPPLY SOLENOID

socket.

is

energised

calling

in

is

for

the

TO

applied

this

course

ON/OFF

occurs

heat.

caus-

The

to

of

9.

10.

11.

(a)

(b)

Fig.

Turn

the

Turn

ON

on

the

electricity

Position

AND

WATER

the

two

~ing.

Turn

1mum.

NOTE:

sensed should

pilot

shape method not

light

vice

Department.

Check

the

tor

and

tion

fluid.

Observe 20mm

velope

the

31b

domestic

the

gas

the

users

or

programmes

the

room

A

spark

will

by

the

automatically

and

of

adjustment.

contact

pilot

valve

the

pilot

25mm

tip

of

electronic

pipe

light

gas

and

hot

at

supply.

if a programmer

size. Refer

Worcester

the

water

the

gas

operating

selector

thermostat

occur

until

circuit.

and

to

If

the

for

gas

connections

flame.

(0.75in

spark

It

and

electrode.

SHrvice

switches

Heat

soundness

thermostat

cock

switch

is

if

fitted

the

pilot

The

smoothly.

item

11

pilot

and

Systems

using

should

1.0in)

and

to

HEATING

fitted

to

24 hrs

is

alight

main

Check

for

sizes

burner

Ltd.

at

the

leakage

be

long

to

OFF.

switch

position

set-

to

max-

and

burner

the

and

will

Ser-

adap-

detec-

between

and

en-

INLET PRESSURE TEST POINT

HIGH/LOW PRESSURE ADJUSTING SCREWS CAP.

SEE

A

HIGH/LOW

SOLENOID

A-

ADJUSTMENT

(HIGH) GAS PRESSURE

B-

ADJUSTMENT PRESSURE

C-

PLASTIC CAP

7.

Position

AND

the

24

in a cold

essary.

8.

Position

programmer heating

cal

supply

SETIING.

the

WATER.

HRS

programmes.

state

the

selector

off.

user's

User's

BURNER

UNDER PLASTIC

BELOW.

SCREW

FOR

SETIING.

SCREW

If

for

is

FOR

operating

a

programmer

about

Operating fitted, switches

switch

BURNER SETIING PRESSURE TEST POINT

240v

ELECTRICAL

SUPPLY PLUG TO

HIGH/LOW

SOLENOID

':

RETAINING

DOMESTIC HEATING (LOW) GAS

switch

Leave

20

minutes,

Switch

both

to

OFF.

is

fitted,

the

Switch

HOT

to

system

venting

to

hot

I

WATER

HEATING

switch

to

work

as nec-

OFF.

water

and

the

electri-

PILOT FLAME

LENGTH L

(20-25mm)

(0.75-l.O)in

(c)

Position programmer

selector supply

(d)

Loosen

31)

12.

Turn Position

AND

tion

13.

When

appliance The

14.3 adjustment. at

Check for

TECHNICAL

Both sures using following ing

(a)

The screws small

to

If

a

(b)

(c)

carefully.

DHW first, HEATING

adjustment the

Allow sure

the

at

the

two

turns,

on

the

HOT

selector

switched

HOT

mbar

5.8mbar the

the

HOT

may the

to

adjust

grey

must

screwdriver

service

to

LOW

sufficient

to

stabilise.

Users

is

switches

the

mains.

pressure

and

electrical

the

User

WATER,

switches

gives

WATER

(5.72in

The

(2.3in

HEATING

heating

DATA-

WATER

be

procedure

points

pressures.

plastic

be

{HIGH)

ensure

SERVICE

of

pressure

Operating

fitted,

position

to

OFF.

test

point

connect a pressure

supply.

Operating

or

if

a

pro~1ramme

to

24hr

to

HEATING

priority

CH

wg).

checked

should

cover

removed.

stable

the

time

to service wg)

requirements.

and

service

Table

and

detailed

over

in

one

gas

ignition

(LOW)

HIGH

setting.

between

gas

will

1.

HEATING

and

be

of

pressure

Switch

the

Isolate

screw

switch

!;etting.

and

HOT

WATER

pressure

not

gas

pressure

gas

pressure

Refer

if

necessary

below.

noted

the

pressure

Refer

to

the

of

can

adjustments

SPARKGAP

'X'

(2.0-2.5)mm (0.08-0.l)in

to

OFF

two

programme

the

electrical

(Refer

gauge.

HOT

normally

service

before

Fig. 31. Place a

slots

must

the

be

adjusted.

setting

to

HEATING

is

fitted,

WATER

SERVICE.

is

pre-set

require

is

pre-set

is

correct

to

Page 2

gas

adjusted

However,

commenc-

adjustment

and

lift

be

adjusted

burner,

influences

for

or

if

Fig.

posi-

the

at

pres-

the

cap

then

Any

pres-

a

28

(d)

Never

14.3mbar

(e)

Operate ensure

from

programmer

14.

ADJUSTING

Refer Allow

(a)

making

(b)

Turn

HEATING

(c)

If

DHW

to

TECHNICAL

10mm clockwise rease

(d) Check

smoothly, proceeding sure.

15.

ADJUSTMENT

Refer

(a)

Turn

thermostat

(b)

If

the

refer

(c)

Using a small wise pressure

(d)

Operate ensure

checking

correctly.

(e)

Using switch eral the

plastic

16.

Position programmer HEATING electrical

OFF. If

the

17.

set

the

setting.

18.

Disconnect point screw

19.

(a)

Switch User's WATER. switches

(b) Set

pilot the red satisfied

(c)

Turn After a short water

so,

then

heat

(d)

Position WATER.

tor

Repeat

(e)

Position and the

Set boiler iators. necessary.

adjust

the

LOW

pressure

setting

above

(5.72in wg).

the

correct

HEATING

models

DHW

to

Fig. 31.

the

boiler

any

adjustments.

the

DHW

thermostat

service

blade

to

increase

pressure

several

by

to

HIGH/LOW

final

to

thermostat

gas

DATA

width

until

times

operating

check

solenoid

pressure

several

settings

by

switching

times

HOT WATER and back. For

use

the

ON/OFF

thermostats.

(HIGH) GAS PRESSURE

fire

for

at

least

10

minutes

to

maximum.

Turn

OFF.

pressure

screwdriver, the

the

needs

adjustment

· Page 2 · Table

and

desired

if

the

turn

counter-clockwise

setting

main

DHW

HEATING

burner

thermostat.

(LOW)

1.

the

screw

is

achieved.

Using

to

ignites

gas

before

OF HEATING (LOW) GAS PRESSURE

to

Fig. 31.

the

DHW

to

HEATING

to

TECHNICAL

to

increase

until

the

that

the

DHW

the

boiler

times

to

cap

the

selector

supply.

thermostat

maximum.

gas

screwdriver

and

the

desired

HEATING

main

gas

valve

and

from

ensure

'C'.

Users' is

fitted

Turn

to

OFF. Set

pressure

DATA·

burner

switches

Table

turn

counter-clockwise

setting

thermostat

ignites

switches

HEATING

HIGH

both

to

gas

both

to

OFF.

appliance

correct

Operating

switch

the

requires

1.

the

screw

is

achieved. several

smoothly

from

HIGH

control

LOW

and

pressures.

switch

HOT

Switch

HEATING

adjustment

'8'

to

decrease

times

before

to

thermostats

back sev-

Replace

to

OFF.

WATER

OFF

thermostats

HEATING GAS PRESSURE has been changed

indicator

screw. when

on Operating

If a programmer to

the

HOT WATER

should

boiler

in

the

on

any

has

turn

bank

If a programmer

switches

item

the

HOT

selector

both

will

Allow

the

pressure

Test

the

appliance

the

electricity

24hr

ignite

should

heat

bank.

appliance

domestic

period

not

yet

off

the

has

reheated

the

User's

to

HOT WATER

19.c. User's

WATER.

switches

appliance

fire

and

to

Check

arrow

on

the

gauge

for

gas

soundness

is

supply

switch

setting.

to

is

thermostat

the

main

commence

Once

the

will

switch

hot

water

the

burners

reached

above.

If a programmer

operate

for

the

tap.

The

and

switch

Operating

is

fitted

Operating

to

24hr

thermostats

commence

for

water

leaks.

data

plate

and

tighten

re-ignited.

and

HEATING

fitted

set

to

MAXIMUM.

burners

to

heat

off.

tap

will

tap,

wait

boiler

will

off.

switch

position

24hr

· HEATING

switch

is

setting.

to

maximum.

to

heat

45

minutes,

to

the

around

position

and

the

selector

smoothly

the

water

bank

has

to

maximum.

re-ignite.

until

fire

until

to

the

to

HEATING

fitted

position

up

the

venting

it

to

the

refer

'A'

dec-

pres-

clock-

LOW

If and

the

new

test

the

HOT

The

and sto-

been

If

hot

does

the

HOT

selec-

OFF.

The rad-

to

as

IMPORTANT: for

water

rectified

20.

Position programmer cal

stats system

hot.

21. Refill 4

19

22. Check

a

including set

15.

When

thermostatic system through these

cases

A

suitable

and

25.

meter

adjustment. To

adjust

hot

water

iator

valves

45

minutes.

ance

the minimum across

Alternatively controlled (3000

a

be be

Btu/h) fitted at

least

16.

Hand

the

retention eration

Advise

sary

to

and

to

maining Finally

ficient adequate ded

by

Worcester and

offer a comprehensive

17.

The

leaks.

to

the

OFF.

from

for

Should

proceeding

the

User's

off

appliance

Turn

correct the customers

before

supply

above.

to

SYSTEM BY-PASS

it

is

possible

the

central

it

is

advisable

position

The

by-pass

pipe

and

fitted

the

by-pass

and

central

and

system

With

heating

the

with

amount

flow

and

the

radiator

under

two

partly

system

open

USER'S

users

instructions

and

instruct

of

the

boiler

the

user

prevent

the

inoperative

advise

and

the

damage

building

the

safe

operation

servicing

Local Gas

Heat

Systems

or

ROUTINE

complete

is

fitted

at Drain the

ON

room

appliance

any

leaks

further.

Operating

switch

mains.

Set

water

drain

points

and

system.

the

gas

operation

thermostat

requirements.

both

from

service

be

found

switch

to

OFF.

the

while

of

the

GUIDANCE

ADJUSTMENT

radiator

heating

for

the

necessary

return

heating

having a minimum

design

lockshield

valves

that

on

circulating

to

fit a system

the

by-pass

should

be

with a suitable

the

heating

by-pass

aid

at

connected

boiler

with

set

of a contact

and

restrict

to

give a temperature

pipes

of

system conditions.

valves

all

times.

are

some

is

should

the fully

15°C

must

both

INSTRUCTIONS

to

the

efficient

of

the

heating/hot

of

the

conditions.

the

boiler

out

at

will

user

water

that

intervals

be

in

and

purchaser

in

the

during

user

or

is

carried

Region.

the heating/hot

to

the

event

frost

purchaser

of

Ltd.

maintenance

CLEANING

must

be

they

to

OFF,

Switch

appliance

the

water

Repeat

(if

Items 3 and

cock. Repeat

User's

fitted)

AND

used

throughout

occasions,

pump

will

by-pass.

shown

in

22mm

valve

be

operated

thermostatic

open

thermometer,

the

by-pass

(27°F).

include

heat

loss

The

radiators

of

which

or

purchaser

and

satisfactory

system.

precautions

water

heating

for

continued

it

is

important

recommen-

pleased

contract.

AND

checked must

or

electri-

thermo-

and

is

Controls

and

stop,

in

Figs. 24

to

provide

for

at

by

one

of

neces-

system

to

discuss

be

if

the

still

Item

leave

flow

in

dia-

on

rad-

least

bal-

the

rise

un-

0.9kW must must

for

op-

re-

ef-

that

a

INSPECTION

To

ensure

it

is

essary

will

and adequate. ried other

continued

recommended

at

regular

depend

usage,

out

Corgi

upon

but

It is

the

by a competent

registered

efficient

that

it

intervals.

the

in

general

law

that

personnel.

operation

is

checked

The

particular

once

any

service

person

of

and

smviced

frequency

installation

per

year

work

such

as

the

appliance

of

conditions

should

must

British

as

nec-

servicing

be

car-

Gas

or

29

1.

(a)

Carry

out a pre-service

ational

faults. (b) Clean (c) (d) (e)

(f) Check

(g) Check

(h)

(j) VERTICAL FLUE

(k)

IF

NEED FROM OBSTRUCTION.

2.

SOME

FULLY IN THE FOLLOWING (a)

NOTE:

system accordance CHECK THE EXPANSION VESSEL PRESSURE (COLD) DESCRIBED IN SECTION 10.

the

burner,

Clean

the

fan,

Clean

the

heat

Clean

the

burner

the

condition

the

sulation

baffle HORIZONTAL

Check

system,

ternal

sound.

Check ted hood are tilators

If check

NECESSARY BRING TO THE USER'S

PRE

Operate which

For valve as

(i) Isolate

(ii) Refer

(iii) Test

(iv) The

and

behind

the

including

connections

the

diverter

and

the

and

internal

sound

are

the

appliance that

TO KEEP

SERVICE CHECK

OF

THE SERVICING POINTS ARE COVERED MORE

the

may

sealed

(pressure

follows:-

to

front

panel

the

for

half a turn,

valve

without If

necessary replace

Section If

the

undertake a spillage

with

if

necessary.

exchanger,

and

condition

the

insulation

the

control

FLUE

flue

terminal

SYSTEMS

flue

system,

connection

and

undamaged.

unobstructed.

has

all

ventilators

ALL

appliance

need

to

systems

relief

the

electrical

Section

and

valve

should

leaking.

18 -

Replacement

appliance

BS 5440:1,

AND

check

necessary.

if

necessary.

pilot

injectors,

of

the

spark

of

the

combustion on

panel.

SYSTEMS

is

the

within

by then

unobstructed

appliance

to

the

air

the

roof

including

to

Ensure

been

installed

are

unobstructed.

VENTILATORS ENTIRELY

INSTRUCTIONS:-

and

rectified

the

valve)

supply

3, Page

cover.

grasping

releasing.

discharge

the

is

fitted

test, at

upon

ADJUST

system,

operation

with

4.

valve

of

with

completion.

be

check

top

and

note

any

if

necessary.

electrode.

the

and

space is

the

during

the

to

Remove

and

Parts.

IF

chamber

inner

face

and

flue

hood

flue

ducts

unobstruc-

the

appliance

air

and

flue

roof

space

in a

compartment

ATTENTION

noting

any

the

service.

of

the

appliance

the

appliance.

the

appliance

turning

as

a VERTICAL FLUE

diverter

INITIAL

NECESSARY,

then

detailed

clockwise

reseat

(Fig 3) in

oper-

in-

of

the

flue

and

in-

are

flue

ducts

ven-

THE

FREE

faults

safety

COLD,

itself

under

SETTING

AS

Fig. 32a

Fig. 32b

INSULATION

INNER CASING FRONT COVER

4 SCREWS

(MARKED X)

(b)

WARNING:

commencing

gas

service

3.

REMOVE

(a)

Remove

base

and

(b)

Remove screws.

Remove

(c)

leasing

Pull

(d)

(e)

(f)

(g)

NOTE:

the reassembly.

the

ectrode. Disconnect

chamber

Release

fold

block. (Fig 32a).

Push

the

left

pilot

assembly.

An

manifold

Disconnect

any

cock.

BURNER

the

front

lift

up.

the

inner

(Fig 32b).

the

combustion

the

four

M5

lead

off

(Fig 32a).

the

slightly

'0'

the

at

the

adaptor.

two

M5

left

hand

and

ring

seal is recessed

block. Replace

the

servicing.

AND

PILOT ASSEMBLY

panel

by

casing

pilot

wall

chamber

screws.

terminal

pipe

(Fig 32a).

screws

of

remove

by

the

or

electrical Turn

pulling

releasing

(Fig 32c).

connector

within

securing

combustion

carefully

into

renew

off

front

the

supply

the

gas

forward

the

cover

at

the

combustion

burner

chamber

the

burner

underside

if

damaged

before

at

four

by

pilot

the

M5

re-

el-

mani-

to

and

of

on

30

Fig. 32c

4.

SERVICING THE BURNER

(See Fig. 32a)

Brush

the

burner

top

and

check

the

(a)

clear.

Any

brush.

bracket

any

water

the

and

the

injector

brush.

not

cause

blockages

the

deposits

pilot

nuts.

electrode

and

burner

and

(Fig 35).

use a wire

damage.

able

(b)

Disconnect burner Clean in

warm

(c) Clean

Remove

screws

bracket M4

screw

(d)

Remove the able

NOTE:

Do

likely

to

5.

REMOVE FAN AND FLUE COLLECTOR HOOD

pilot

pipe

(Fig. 36a).

from

or

usinQ a

shield

and

shield

Clean

nut.

Clean

injector.

from

may

at

Remove

the

suitable pilot

by

if

necessary.

by

unscrewing

if

the

burner

brush

be

the

pilot

unscrewing

necessary.

Clean

or

ASSEMBLY

Refer

to

Fig. 33.

Disconnect

(a)

off

important. Disconnect

the

(b)

Disconnect

connectors;

left

(c)

Remove washers tor

(d)

Remove

the

boiler and the top

the

fan

hand

hood

LIVE

housing

baffle

body.

the

back of

the

and

the

RHS

side

of

the

two

at

the

back

panel.

the

screw

behind

(Fig 32a).

DHW

limit

of

the

appliance.

fan

supply

NEUTRAL

EARTH

by

removing

two

fan

of

the

flue

M5

left

and

the

thermostat

baffle.

leads

connectors.

lead

from

sensing

fan

collector hexagon

right

nut

control

Remove

Lift

the

scroll

hand

attaching

removed

underside

the

injector

brush.

burner.

any

venturi

any

at

the

the M5

tubes

outlet

hood.

head

sides

panel

the

fan

cable

baffle

flame

using a suit-

of

pilot

(Fig 36a).

the

Remove

the

deposits

using a suit-

other

implement

fan Polarity

earthing nut.

from

and

screws

of

the

to

the

sensing

from

the

up

and

by

remaining

by

the

bottom top

ports

the

pilot

injector.

rinsing

two

the

pilot

from

pulling

is

stud

brass

at

collec-

of

tubes

clips

out

of

are

M4

not

on

the

and

of

the

on

the

Fig. 33

BAF

(e)

Slacken the chamber ward

When slots, up clear

6.

CLEANING THE FAN

efully fan

7.

CLEANING THE HEAT EXCHANGER

(a)

Cover inlet

(b)

(c)

Remove combustion

8.

9.

(a) Check

(b) Refit

(c) Fit

the

four

M5

slotted

collector

about

the

lift

first.

of

Inspect ness.

Any

removed

sharp

instruments

motor

Examine side.

If

lowing

within

Using a suitable the

heat

hood

sufficiently

1 Omm. (Fig 33)

screw

the

rear

Rotate

the

appliance.

the

fan

accumulation

or

fan

heat

exchanger

necessary

procedure.

the

pilot

the

exchanger any

deposits

chamber.

heads

of

the

assembly

motor

using a soft

to

wheel.

remove

Refer

gas

combustion

brush,

and

to

the

for

the

are

the

fan/collector

and

of

be

used

fins

to

inlet

adaptor

clean

the

which

head

top

hood

at

the

fan

dust

brush

from

any

Fig. 34.

chamber.

fins.

fall

COMBUSTION CHAMBER INSULATION

Examine omit aged

PLACEMENT

the

combustion

replace

combustion

as

instructed

OF

PARTS-

chamber

under

Page

RE-ASSEMBLY

Re-assemble

the

fan

the

combustion

the chamber. ated

positively

loosely

at

the

back

panel.

Push

the

collector chamber ing

gasket

screws

tion.

the

collector

outlet

assembly

Ensure

the

left

and

collector

are

engaged

compressed.

sufficiently

boiler

and

the

chamber.

the

within

two

M5

right

hood

to

as

follows:-

hood/fan

area

If

to

the

four

the

keyhole

hex.

hand

sides

back

to

the

in

their

Tighten

hold

the

of

necessary

top

M5

head

top

screws

of

to

back

forwards

impellor

or

fluff

or

which

may

the

deposits

and

the

inside

to

the

insulation.

front

Section

assembly

contact

of

fixing

slots.

screws

of

the

until

the

of

slots

and

the

two

collector

(X)

the

be

of

hood

and

should

by

top

using

the

bottom

panel.

seals with replace

the

screws

and

collector

screws

the

hood

the

blowing.

H5

attaching

combustion

drawn

for-

keyhole

assembly

upwards,

for

cleanli-

be car-

under-

the

main

surface

of

Do

If

dam-

18 -

around

the

top

them.

are

washers

hood

fixing

fan

hex

in

No

the

fol-

gas

the

not RE-

loc-

sealhead posi-

damage

and

combustion

of

31

Fig.

34

COMBUSTION

FIXING SCREWS

CHAMBER

(e)

Set

to

(f)

Refer ANCE. structions

(g)

Before ensure the

the

three

OFF.

to

Follow

leaving

no

appliance

position

Section

11

to

flammable

casing.

switch

orr

programmer

14 -COMMISSIONING

the

22. the

procedures

site

the

material

required

service

has

THE APPLI·

engineer

been

left

if

under

should

inside

fitted

in-

DO

NOT screws combustion

(d) Refit

the THE

(e) Refit

Check cable

back (f) Refit (g)

If Refit

pilot jector should erosion.

(h)

Inspect age

(j) Refit

under

fitted

not Secure

(k)

Reconnect

tightness (I)

Refit

(m)

Replace boiler

OVER-TIGHTEN.

attaching

the

fan

fan. DO

STUD

the

baffle

the

are

of

the

burner

removed

the

pilot

burner

is clean

be

(See

the

or

deterioriation

the

correctly

displaced

the

ignitor the

front

chamber.

sensing

NOT

PROVIDED.

plate

sensing

routed

baffle

refit

injector

assembly

and

replaced

Section

'0'

ring

'0'

ring

combustion

in

and

burner the

pilot

at

the

adaptor

combustion

cover.

10. TEST APPLIANCE

(a) Turn

(b) Refer

(c) Check

(d)

on reconnect switch,

or

panel

tion

With

hot

thermostat

and lies

the

or

programmer,

CONTINUOUS.

to

the

and

for

gas

through

the

central

water

check

hot

water

gas

the

electrical

lighting

light

soundness

the

operates

is

satisfied,

that

to

the

BOILER

THERMOSTAT

the

collector

tubes

OMIT

THE EARTH CONNECTION

behind

tubes

correctly

plate. injector the

lead

pilot

and

not

if

18-

seal,

it

seal

the

rear

the

at

the

pipe

to

AND

supply

instructions

boiler.

viewing

heating

diverter

the

central

it

must

chamber.

if

correctly.

to

making

blocked.

and

pilot

and

the

INSTALLATION

at

supply.

switch

LIMIT

POCKET

Tighten

hood

and

the

control

and

dhw

using

the

burner.

bracket

manifold

fitted,

window.

and

the

pilot

sure

shows

if

and

off,

The

signs

Replacement

there

is

be

replaced.

the

burner

Ensure

location,

tubing

at

the

pilot

electrode.

chamber

the

gas

Set

to

HEATING

check

the

valve

heating

PHIAL

BOILER

THERMOSTAT

the

to

electrical

clips

supply

that

any

the

is

block.

adaptor.

burner

front

service

the

LIMIT

CAPILLARY

front

M5

the

top

panel.

limit

thermostat

fixed

shield.

pipe

the

spark

electrode

of

damage

of

Parts).

sign

into the

burner

'0'

ring

not

damaged.

Check

connections.

cover

cock

three

& WATER

on

the

jacket

main

burner

that

the

When

central

operates

circuit.

the

heating

and

fixing

of

the

leads

to

TO

to

the

to

the

pilot

in-

or

of

dam-

position

seal is

for

and

position

front

igni-

domestic

priority

on

supp-

is

18.

Refer 17 - ROUTINE ceeding.

WARNING: and mencing

1.

(a)

(b) Pull

(c)

(d) Release

(e) Push

Note manifold assembly.

(f)

2. (a)

REPLACEMENT

to

Section

turn

TO

Refer

Remove combustion

ectrode.

Disconnect chamber

ifold

the pilot

Remove pilot

17.4) re-assemble

TO

Remove

Disconnect off any

REPLACE BURNER

to

Fig. 32a, Fig 32b, Fib

the

lead

the

block.

the

left

slightly

assembly.

the

'0'

block.

the injector and

REPLACE THE

1.

(b)

Remove

(c)

Reassemble or

existing

3.

(a)

jointing

TO

SPARK

36a)

Remove

compound.

REPLACE THE PILOT BURNER, PILOT SHIELD,

1.

(b)

Disconnect remove. may

be

3 -

REMOVAL

CLEANING

the

gas

at

further

the

at

left

ring

fit

the

ELECTRODE

the

necessary

work.

front

chamber

off

the

pilot

the

adaptor.

two

M5

hand

and

seal recessed

Replace,

main

and these in

reverse

burner

main

the

main

components

burner

the

pilot

The

pilot

wall

injector

complete

components

MAIN

injector

AND

the

electrical

the

gas

cover,

front

push

on

pipe

screws

of

the

remove

or

renew

order.

INJECTOR

assembly

burner

as

AND/OR

assembly

pipe

injector

to

carefully

OF

PARTS

OF

CABINET

INSPECTION

supply

service

3L'c.

inner

cover.

connector

within

securing

combustion

carefully

into

the

if

(Section

pilot

to

the

as

described

from

the

and

necessary.

PILOT INJECTOR (Fig

as

described

from

the

may

ease

cock

front

at

the

underside

damaged,

18.2),

assembly

new

burner

injector

pilot

now

be

the

injector

and

at

before

burner

Use a little

Section

before

pro-

the

mains

com-

cover

and

the

pilot

el-

combustion

man-

chamber burner

pilot

burner

in

(Fig 35). using

burner

removed,

of

on

pipe,

(Section

Section

in

Section

free.

to

and

the

re-

and

new

and

it

32

(c)

Reassemble necessary.

Release

(d)

to

the

pilot

(e)

Reassemble necessary. (0.08-0.1in)

(f)

Remove pilot

shield

Reassemble

(g)

necessary.

PILOT BRACKET

REMAINING

AND

SCREW

-w

PILOT SHIELD 2

NUTS

AND

SCREWS

using

the

hexagon

assembly

using

Check

(Section

the

two

to

the

using a new

NUT

new

that

14.11b).

M4

pilot

or

nut

securing

and

remove.

or

the

screws

bracket.

existing

spark

and

or

existing

components

the

spark

components

gap

is

nuts

securing

component

as

electrode

as

2.0-2.5mm

the

as

Fig. 36b Underside of Collector Hood

4.

TO

REPLACE

Refer

to

(a)

Remove inner

front

(b) Pull

(c)

(d)

(e) Fit a

5.

(a)

(b)

(c)

(d) Fit a

6.

(a)

the

electrode. Pull

the

ence

control

Remove (Fig 32a).

Remo~e

attachmg the

lead

the

sealing

grommet

replacement

order. Ensure

pilot

pipe

TO REPLACE THE FAN

Refer

to

Remove lowing Cleaning fan

sealing

Slacken ing

it

to

Remove housing are

positioned

36b).

new

to

Section

TO REPLACE THE SEQUENCE CONTROL BOARD

Refer Remove

facia

(Section

THE ELECTRODE LEAD

Figs. 32a, Fig 36a, Fig 37.

the

lead

from

the

Fig. 33

the

the the

the

to

Fig. 37.

the

appliance

cover.

off

(Fig 32a).

off

board

sealing

two

the

electrode

the

cover

in

the

lead is

and

not

fan

procedure

and

Inspection,

gasket

screw collector

three

the

top

on

fan

and

17 -

Subsections

the

appliance

3).

the

control

and

front

terminal

(Fig 37).

cover,

re-usable

lead

boiler

by

and

the

panel

lead

and

correctly

twisted.

collector

under

the

hood

of

the

underside

front

Subsection

collector

(Fig 36b).

(A) at

slotted

the

reassemble

cover

connector -at

connector

one

M5

plastic

to

the

pilot

passing

other

back

head

9a

one

through

base.

reassemble

routed,

hood

Section

top

of

the

panel.

screws

hood.

of

the

in

reverse

to

9e.

cover,

top

hex

cable

clamped

assembly

top

cover

the

at

the

headscrew

pipe.

end

the

in

17 -

5.

Remove

fan

outlet,

(Fig 33).

fixing

The

top

panel.

order.

cover

and

spark

sequ-

clamps

Remove through

plastic

reverse

to

the

by

fol-

Routine

the

screws

(Fig

Refer

and

fix-

fan

(b) Pull

(c) (d) Release

(e) Pull

(f)

(g)

the nection, control

Disconnect

ing

post

approximately

returning.

the

plate

until

Locate and

push

end

of Reassemble (i)

The at trol

(ii)

The

minals.

only

Fig.

37

~~

..

spark

at

board.

the

pulling

board

the

back

each

spark

the

board.

Molex

fit

FAN

TOP

~-

electrode

the

top

the

four

plastic

3mm

it

is free.

new

squarely

post

in

the electrode

top

right

Plugs

the

socket

SENSING FRONT)(+

TERMINAL

.

right

Molex catch

the

to

off

the

board

clicks

reverse

hand

plugs

are

PLUG-IN

cable

off

the

hand

corner

plugs.

on

the

printed

prevent

over

into

are

not

they

circuit

the

remainder

the

until

the

place.

order

is

connected

corner

fitted

interchangeable

were

TUBES (-PRESSURE

PRESSURE TOP REAR)

.SPARK

RAIL CABLE

MOLE PLUGS

of

end

of

board

plastic

of

four

mounting

plastic

and

ensure:

to

of

the

to

the

removed

X

LIMIT

THERMOSTAT

electrical

the

sequence

con-

sequence

each

mount-

forward

catch

from

mounting

posts

catch

on

the

terminal

con-

correct

from.

ELECTRODE

and

ter-

will

33

7.

TO REPLACE THE FAN PRESSURE SWITCH

Refer

to

Fig. 37.

(a)

Remove facia.

Pull

of

Pull bottom

Remove

to

Replace

order

(i)

(ii)

8.

TO REPLACE THE CENTRAL HEATING OVERHEAT

off

the

pressure

off

of

two

the

control

the

and

The

three

correct

The

flexible must on

the

appliance

two

switch.

the

three

the

pressure

M5

panel

new

ensure:

terminals

be

connected

pressure

flexible

electrical

screws

and

fan

electrical

(Fig 28).

tube

switch

front

tubes

switch.

holding

remove

pressure

connections

ends

are

to

the

(+to

panel,

top

from

the

top

connections

the

pressure

the

switch.

switch

in

are

made

marked + and-

correct

pressure

rear).

THERMOSTAT

(a)

Remove

casing

Remove

(b)

the the and the appliance.

(c)

Remove thermostat

Remove

(d)

stat agon

Remove

(e)

feed side

(f) Pull

stat.

Remove

(g)

washer Ease

(h)

Disconnect

the

board. grommet

(j) Pass

through

moved

(k) Replace

suring:-

(i) (ii) (iii)

(iv)

NOTE:

inside

and

baffle

boiler.

dhw

plate.

capillary

head

it

out

of

the

off

the

Polarity

the

top

the

and

The

Any SIDE

ie

in

The

During

the

thermostat

the

appliance

facia.

(Section

the

hex

head

plate

behind

(Fig 32a).

limit

thermostat

Lift

the

split

phial

pocket. (Fig 34).

the

sealing

tube

retaining

the

thermostat

of

the

boiler

casing.

two

electrical

is

not

the

thermostat

situated

Withdraw

the

with a new

split

sealing

surplus the

electrode

under

thermostat

the

electrode

right

hand

in

the

bottom

capillary

grommet.

renewed.

cover

the

capillary

control

space

manufacture

front

screw,

the

Remove

plate

up

from

cover

passes

screw.

exposed

important.

the

out

side

the

of

tube

The

thermostat

is

replaced.

is

panel

below

lead is

phial

pocket

panel,

3) (Fig 32c). attaching

control

the

cable

from

and

out

the

end

through

by

unscrewing

(Fig 34).

phial

from

hole

at

connectors

(Fig 37).

centre

of

lead

correctly

reconnected.

thermal

post

control

its

locating

lead

from

of

the

through

the

control

and

thermostat

in

tube

is

and

combustion

the

control

and

replaced.

coiled

top

the

panel

fan

sensing

the

of

the

of

the

which

its

the

top

at

fixing

panel.

hole.

the

sequence

panel.

can

reverse

panel.

grease

may

be

cover,

to

clips

neatly,

cover

(Section

from

switch

the

reverse

bottom the

behind

top

overheat

the

thermo-

the

M5

pocket

right

the

thermo-

nut

terminal

control

the

(Fig. 37).

phial

then

order,

chamber,

is

smeared

left.

and

the

to

the

and

points

inner

top

tubes

of

the

hex-

and

hand

and

plastic

be re-

en-

OUT-

3)

of of

at

up

Fig. 38

Fig. 39

THE PROGRAMMER (Fig. 39)

(i)

Remove the and

(ii) Refit

assemble

10. TO REPLACE THE SUPPRESSOR

Refer

to

Fig 40.

(a)

Remove facia.

Remove

(b)

under thermostat gain

(c)

The

suppressor

and

is

the

screw

clip.

the programmer remove

the

(Section

the

LHS

mounting

access

to

held

by

and

four

M4

retaining

the

programmer.

replacement

in

reverse

appliance

3).

two

of

the

a 'P'

ease

order.

M5

hex.

the

control

plate

suppressor.

is

located

clip

the

SUPPRESSOF~

pozidrive

programmer

front

head

in

below

secured

suppressor

screws

brackets

panel

top

screws,

panel,

position.

the

by a screw.

clear

to

the

and

cover

positioned

which

Lift

the

terminal

of

holding

facia

re-

and

fix

the

plate

strips

Loosen

the

•p··

9.

TO REPLACE THE THREE POSITION SWITCH PROGRAMMER

Remove

facia.

Separate switch/programmer.

the

(Section

the

appliance

3).

push-on

front

panel,

connections

from

top

the

3-POSITION SWITCH (Fig 38)

(i)

(ii)

Squeeze and

facia.

Snap of push-on panels.

remove

in

the

the wiring

together

connections.

the

switch

replacement

diagram

two

Refit

plastic

from

switch

(Fig 29)

the

retammg

the

and

facia

cover

rear

front

with

the

connect

and

cabinet

of

OR

and

the

lugs

the

aid the

DOMESTIC HOT WATER HIGH LIMIT THERMOSTAT

34

(d)

Disconnect N2

and 7 on

(e) Replace

the

reverse

the

with a new

order.

11. TO REPLACE THE

Refer

to

Fig. 33.

(a)

Remove

tion

Disconnect

(b)

strip

5). Refer that leave

(c) Release

loose leads

(d)

Remove sing back

(e)

Remove heat

(f) Fit a

strain

ectrical

connections

(g)

Ensure are

NOTE:

tant

to

contact

ing

bracket.

red

on

Fig.

EARTH SCREW

appliance

3). the

in

the

left

to

the

correct

any

leads

the

strain

section

from

tubes of

thermostat

new

relief

clipped

When

ensure

surfaces

the

surfaces

of

the

dhw

from

the

baffle

the

two

thermostat

bush

wiring

diagram

are

the

thermostat correctly

fitting a replacement

that

of

During

41

hand

control

both manufacture and

suppressor

terminal

suppressor

Refer

to

DHW

OVERHEAT THERMOSTAT

front

thermostat

side

wiring

diagram

leads

loose

in

the

relief

the

bush

box.

overheat

the

from

plate

behind

M3

taptite

to

the

flow

and

has been

(Fig. 29)

made.

cable

to

the

no

foreign

the

may

be left.

leads

strip

panel

of

are

bush and

reconnect

thermostat

from

and

wiring

and

leads

the

control

(Fig. 28)

disconnected.

control

by

carefully

thermostat

the

support

the

screws pipe.

replaced.

to

and

back

of

thermostat

matter

thermal

the

remove.

reassemble

diagram

control

ensure

fan

is

(Fig 28).

top

cover.

at

the

panel

to

box.

compressing

withdraw

and

clips

panel.

holding

ensuring

Refer

the

sensing

the

baffle

it

present

and

the

grease

terminals

(Sec-

terminal

(4

and

ensure

Do

not

the the

fan

sen-

on

the

over-

that

the

to

the

el-

correct

tubes

plate.

is

imporon

the

mount-

is

smea-

in

(e) Prise

(f) Push

(g)

(h) Fit

(j) Refit

NOTE:

inside

off

of

the

thermostat.

the

spindle Withdraw through

control

rear

box.

the

verse

order. thermostat and

must

the

control position without hind

the

hot

surface.

ced

into

the

of

the

During

the

thermostat

the

two

thermostat

from

the

plastic

new

thermostat

The

must

be

uncoiled

box

the

excess

tight

bends,

control

Ensure

the

thermostat

two

push

thermostat.

manufacture

electrical

body

mounting

thermostat

grommet

capillary

be

positioned

to

opening.

capillary

and

panel

that

on

Polarity

phial

socket

connections

back

bracket.

threading

in

the

and

reassemble

of

assist

With

positioned

but

not

the

retaining

pocket. electrical

is

thermal

and

from

to

disengage

the

rear

of

the

at

the

its

passage

the

thermostat

must

so

in

contact

connectors

not

important.

grease

may

be left.

the

capillary

the

electrical

in

the replacement top

(Fig 41)

through

be

recoiled,

that

it

with

clip

is repla-

at

is

smeared

13. TO REPLACE THE CENTRAL HEATING CONTROL

THERMOSTAT

(a)

Remove

facia.

(b)

Using a pair clip

pipe

Remove

(c)

under thermostats

olate

(d)

Remove washer.

(e)

Remove of

(f) Push

spindle

(g)

Withdraw through control

(h) Fit

verse thermostat and the position without

hind hot

ced

Fig. 42.

(Section

from

and

the

forward

the

thermostat.

the

from

box.

the

order.

must

control

the surface. into

the

appliance

3).

of

the

thermostat

remove

the

two

LHS

mounting

as

the

thermostat

the

two

thermostat

the

plastic

new

thermostat

must

be

uncoiled

box

the

excess

tight

bends,

control

Ensure

the

thermostat

Domestic high

limit

long

nose

the

thermostat

M5

hex.

of

the

far

as

possible.

electrical

body

mounting

thermostat

grommet

The

capillary

be

positioned

to

opening.

capillary

and

panel

that

hot

water

thermostat

front

panel,

pliers

pocket

head control plate

in

central

connections

back

bracket.

threading

in

the

and

reassemble

assist

With

positioned

but

not

the

retaining

pocket.

Domestic overheat

top

pull

the

situated

phial.

(Fig 42).

screws

panel

which

position.

(Fig

40;,

clamping

from

to

disengage

the

rear

o·f

of

the

at

the

its passage

the

thermostat

must

so

in

contact

cover

retaining

in

the

positioned

fix

Draw

(Fig

41

nut

the

capillary

the

electrical

in

the replacement top

(Fig 41)

through

be

recoiled,

that

it

with

clip

is repla-

hot

water

thermostat

rear

the

re-

in

is be-

any

the

and

flow

the

).

and

rear

the

re-

in

is be-

any

HOT

c

WATER

CONTROL

THERMOSTAT

12. TO REPLACE THE

(a)

Remove facia.

(b)

Using a pair

clip

DHW rear

(c)

Remove under thermostats plate

(d)

Remove

the

(Section

from

inlet

and

remove the

the

forward

the

appliance

3).

of

the

thermostat

pipe

two

LHS

mounting

as

central

long

on

the

of

far

DHW

M5

the

CENTRAL

HEATING

CONTROL

THERMOSTAT

CONTROL THERMOSTAT

front

panel,

top

nose

pliers

pull

the

adjacent

heat

phial.

(Fig 44).

screws,

which

position.

(Fig 40) (Fig

and

washer.

the

top

thermostat

hex

head

control

plate

as

possible.

clamping

pocket

of

the

panel,

in

nut

cover

retaining

to

bank

at

positioned

fix

Draw

41

).

and

the the

the

Safety

35

valve

Centra control

heating

thermostat

(j) Refit

NOTE:

inside

rear

the

of

the

During

thermostat

two

push

thermostat.

manufacture

phial

on

electrical

Polarity

pocket

thermal

and

connectors

is

not

grease

may

important.

is

smeared

be left.

14. TO REPLACE THE RELAY

Refer

to

Fig. 37

(a)

Remove facia.

(b) Ease

horizontally.

(d)

The into

Reassemble

(Section

the

new

the

base

the

appliance

3).

relay

from

relay

will

fit

until

fully

in reverse order.

front

the

base

in

one

direction

located. Do

panel,

by

pulling

only. Push

not

top

force

cover

to

the

it

into

the

15. TO REPLACE THE PUMP DELAY TIMER BOARD

Refer

to

Fig. 40

and

Fig 41.

(a)

Remove

facia.

(b)

Remove under thermostat's plate

Release

(c)

ing roximately catch electrical ches.

Pull

(d) (e)

Disconnect

strip.

(f)

Locate

top,

squarely post

(g)

Reconnect gram

leads correctly.

Reassemble

(Section

the

forward

the

post

from

the

board

the

over clicks

(Fig. 28).

the

appliance

3).

the

two

LHS

of

mounting

to

facilitate

plastic

pulling

the 3mm returning.

screw

driver

off

the

electrical

replacement

the

four

until

the

into

place.

the

leads

in

reverse

M5

the

catch

printed

each

the

mounting

plastic

with

It

is

front

hex.

head

control

plate

access.

on

the

circuit

time

It

may

be

to

assist

mounting

connections

board,

catch

the

important

order.

panel,

screws

panel,

in

position.

end

to

prevent necessary in

posts.

with

posts

on

aid

of

to

top

cover

positioned

which

of

each

board

the

releasing

at

the

leads

and

push

the

end

the

wiring

reconnect

Move

mount-

back

to

the

terminal

of

16. TO REPLACE THE GAS VALVE

Refer

to

Fig.

31

and

Fig. 43.

(a)

(b)

Remove strip (Section

Remove leade

Disconnect valve.

the

below

3) the

to

the

(Fig 43).

appliance

the

door

(Fig 32b).

two

plastic

pilot

pipe.

the

pilot

front

by

clips

pipe

panel.

releasing

attaching

at

the

Remove

the

five

the

adapter

the

electrode

and

at

the

and

right

relay

place.

and

fix

the the

app-

plastic

use an

cat-

at

the

back

each

dia-

the

kick

screws

gas

(c)

Unscrew connection set

NOTE:

connectable.

(d) Release

cock. (Fig. 43).

(e)

Remove

hand gas line flange connection and out

Remove

(f)

Remove from inlet

(g)

Using BS female valve inlet

(h) Fit

taking care

(i)

Turn gas soundness and undertake dure

the

of

the

5292

the

plugs

terminals.

plugs

the

inlet gas

the

four

of

the

front

the

flange sealing washer. Renew

the

iron

tapping.

an

approved

fit

the

elbow

tapping.

new

gas valve and reassemble in reverse order,

to

on

the

gas

in accordance

retaining screws

then pull each

are

dissimilar

union

connection at

M5

hex. head screws securing

of

the

appliance. (Fig. 43).

female

half

of

male/female

jointing

female

supplied and fitted

renew

the

supply

with

the

elbow

compound

half

of

the

flange washer.

at

the

Section

from

the

solenoid electrical

plug

off

and

therefore

withdraw

brass

union

fixed

to

brass

union

to

the

gas service cock. Check

the

commissioning

14.

17. TO REPLACE THE CIRCULATING PUMP

(a)

Remove (Section

(b)

Turn and

(c)

Undo

from

NOTE: A

(d)

Remove on Refer

PUMP

the

3).

off

the

outlet

the

between

residue

the

pump

to

diagram

TERMINAL

appliance

isolating

of

the

two

the

of

water

two

and

pump.

union

pipework.

will

screws

disconnect

below.

BLOCK

front

valves

Refer

nuts

remain

holding

panel

mounted

to

Fig 44.

and

in the

the

and

remove

the

electrical

of

its respective

not

inter-

the

gas service

the

right

the

valve

on

assembly.

connector

the

gas valve

complying

replacement gas

on

pump.

electrical

to

top

the

with

male/

for

proce-

cover.

inlet

pump

cover leads.

Fig. 43

INLET GAS UNION COCK

PILOT PIPE

SOLENOID ELECTRICAL CONNECTION

PLUGS

DRAIN COCK

(e)

Install a replacement

sealing

NOTE:

pump placement adjuster

The

should

pump,

is

fitted.

washers.

direction

point

towards

should

flow

circulating

indicator

the

be set

18. TO REPLACE THE DIVERTER VALVE

Follow

the

(Section

NOTE: A

work. (a)

Refer

Disconnect strip. fully

(b)

Undo

the

Remove

(c)

valve,

NOTE:

the

nections.

21)

residue

to

the

Release

withdraw

the

top

return

the

before

Some

valve

procedure

up

of

appliance

the

three

pipe

return

removing

manipulation

from

to

and

water

diverter

cable

the

lead

union

the

to

remove

including

will

wiring

valve

restraining

from

connections

union

pipe

union

the

remaining

remain

above

36

rear

of

at

maximum

diagram.

leads

the

elbow

valve. may

pump

on

the

heat

item

in

the

at

bush

control

at

the

valve

be

necessary

union

boiler.

speed

21

(h).

boiler

Fig 28.

the

box.

the

on

with

new

circulating

The

re-

if

an

exchanger

pipe-

terminal

and

care-

valve

and

(Fig 45). top

of

the

to

free

stub

con-

(d) Fit

override

Refit

union

Leave all

(e) Refit

Fig. 44

Union

It

-

•

(f)

Refit tighten

(g)

Open as necessary. matic tions

(h)

Reconnect that When wiring

(j)

Reassemble and

the

replacement

lever

the

at

the

heat

Tundish

the

all

air

10

and

the

cable

making

diagram.

system

diverter

underneath.

top

union

bottom

unions

elbow,

of

slack

exchanger

the

at

Domestic Hot Water High Limit Thermostat

Auto Air Vent Safety

union

at

the

unions

radiator

The

vent

on

11

the

operate

RHS

securely. valves

appliance

the

heat

). leads

at

restraining

electrical

(Fig 28).

appliance

satisfactorily.

the

valve

with

the

top

union

valve this using

body.

stage.

new

union

and

washers.

Pump

Valve

of

the

diverter

and

fill

the

is

fitted

bank. (See Fig 44). (Sec-

terminal

bush

has

connections

and

check

system

with

strip,

been

refer

the

valve

venting

an

ensuring

replaced.

appliance

manual

the

and

auto-

to

the

19. TO REPLACE THE DOMESTIC HOT OR

FLOW REGULA TOR

NOTE:

fed discard.

tained.

(a)

If off sure

If the

Remove

(b)

To access liance

(c)

Depending (i)

(iii)

(d)

Disconnect compression

inlet

(e)

Disconnect

washer,

be

(f) Fit a

first, the should

TO REPLACE THE

Refer

Drain

(a)

tems.

(b)

Remove

(c)

Working

move

pliers

(d) Fit

ting

(e)

Open ting

(f) Check

20. THE HEAT

Should exchanger hard Worcester

be

contacted

hot

the

by

the

cistern

remove

If safety heating

If

(ii)

safety If

sion down Fig 43). valve valve feed assembly.

union.

necessary

and

fibre

to

Fig 44.

down

through

the

compound.

as

the

water

A

flow

regulator

water

supply

The

filter

dhw

cold

supply

opening a dhw

supply

to

(Figs 23a

the

wire

new

be

supply

to

the

is

from a cistern,

and

drain

the

front

filter

the

union

and

upon

central

valve

system

central

valve

CH

system

pipe

will

the

central

Disconnect

discharge

(Fig 23a)

pipe

union

Access is

the

15mm

union

the

cold filter to

prise

filter/regulator

reassemble

sealing

used.

AUTOMATIC

the

cock

the

appliance

in

the

auto

radiator

the

heating

space air

the

system

(Drain

the

replacement

all

necessary.

that

BANK

heat

bank

within

it

Systems

who

become

without

will

area

Heat

system.

and

appliance

it

down

panel

or

regulator,

at

the

47)

the

type

heating

plugged,

and

heating

not

fitted

is

be

pipe and (Fig 47).

elbow

inlet

and

the

in

washer.

Fig 43).

front

behind

vent

slot

in

air

valves

operates

fail

or

suitable

Ltd.

advise

is

not

required

sealing

is tap.

capped.

heating

union

plastic

and

vent

the

scaled

If

direct

and

turn

at a dhw

and

top

it

dhw

cold

and

release it.

of

system

is

open

drain

remove

is

open

access is

sealed

system.

the

union

is

attached

at

the

Remove

now

available.

at

fitted

union.

flow

regulator

small

the

reverse

No

AIR

VENT

domestic

panel

the

using a pair

the

bulkhead.

using

and

re-fill

domestic

up

water

Service

on

suitable

fitted

washer

from

release

off

covel-

is

necessary

down

the

In

where

internal

the

to

Remove

regulator.

from

diameter

sealin!~

and

control

an

the

satisfactorily.

due

Department

21. TO REPLACE THE HEAT EXCHANGER

(a) (b)

(c)

(d) (e)

(f)

Remove

Drain (Drain

Remove hex

Cover Slacken

at top

Slacken erter

the

of

down cock

head

the

point the

valve.

kickstrip,

the

Fig 43).

the

inner

screws.

burner

the

two where

boiler.

the

union

(Fig 45).

front

panel

heating

casing

and

pilot

pozidrive

the

flow

(Fig 33).

at

the

and

by

releasing

assembly. screws

pipe

right

hand

top

hot

retaining

passes

Wi~TER

the

inlet

used:-

vented plug

vented

available.

primary

this

Rc1/7

the

order,

hot

approved

hot treatment, remedial

water

side

FILTER

on a cistern remove must

mains

any

the

supply

tap.

(Section

to

of

the

and

the

for

access.

and

expan-

case

(Drain

the

to

the

expansion

the

pipework

(1!7in

dhw

the

sealing

its

housing.

section

replacing

compound

water

top

cover.

panel

of

gland

system,

water

to

its

use

cover.

system.

the

four

the

through

of

the

and

be re-

turn

pres-

to

3).

gain

app-

the

central

the

drain

cock safety safety

BSP)

cold

It

may

sys-

re-

nut

join-

ven-

heat

in

then should action.

M5

seal

the

div-

a

37

(g) Release

(Fig 34). Ease back

of

(h)

Remove

appliance.

(j) Fit a

verse mountings.

(k)

Open as necessary. airventontheheatbank. Check

(I)

Reassemble Check

isfactorily.

22.

TO REPLACE THE COMBUSTION CHAMBER

the

heat

new

order

all

that

the

two

exchanger

the

heat

ensuring

Do

radiator

The

the

heat

exchanger

the

pipework

to

exchanger

that

not

forget

valves

and

appliance

cap

is loose.

appliance.

appliance

drop

through

and it

is

to

fit

re-fill

is

fitted

(Fig44)

and

union

and

allow

slightly.

the

reassemble

correctly

new

union

the

system,

with

(Sections

system

operates

connections

the

front

of

in

the

seated

in

washers.

venting

an

automatic 10and

sat-

the

re-

its

11).

INSULATION

(a)

Remove Section

(b)

Remove not chamber

(c) Refit

verse mountings.

(d)

Open as necessary. air cap

(e)

Reassemble Check isfactorily.

21

forgetting

the

order

all

radiator

vent

on

is loose.

that

the

above.

the

front heat

Do

the

heat

exchanger

old

insulation the cover.

exchanger

ensuring

not

valves

The

appliance

heat

the

appliance.

appliance

pad

that

forget

and

bank.

fitted

and

it

to

re-fill

is

See Fig

and

as

described

pads

and

inside

reassemble

is

correctly

fit

new

the

fitted

with

44.

system

under

replace

the

combustion

in

seated

washers.

system,

an

automatic

Check

operates

sub-

them,

the

in

venting

that

the

sat-

re-

its

23. TO REPLACE THE BOILER FRONT COVER INNER CASING

(a)

Remove

(b)

Remove the

(c)

Remove placement the inner

(d) Refit

Operate (inward)

(e) Refit

four

strip

casing

the

SEAL.

the

front

the

M5

hex

the

strip

passes

and

inner

the

appliance

around

front

panel.

inner

casing

head

damaged

using

completely

across

casing,

the

inner

panel.

front

screws.

sealing

silicone

around

the

centre

tightening

to

ensure

casing

cover

(Fig 32b).

strip

and

adhesive.

the

with

the

screws

there

seal.

by

Check

edge

no

are

fit

gaps.

releasing

the

re-

that

of

the

evenly.

no

leaks

24. TO REPLACE THE SEAL BETWEEN THE COLLECTOR

HOOD

AND

BOILER TOP

(a)

Remove

assembly Cleaning

(b)

Remove placement home hood. seal

Reassemble

the

8venly

Ensure

touch.

combined

as

detailed

and

Inspection -sub-section

the

damaged

strip.

around

there

the

appliance

Check

is

fan

under

sealing

that

all

four

no

gap

and

the

in

reverse

flue

Section

strip

new

sides

where

collector

17 -

5.

and

fit

strip

is

of

the

ends

order.

hood

Routine

the

re-

pressed

collector

of

the

25. TO REPLACE THE FAN OUTLET SEALING GASKET

(a)

(b)

Remove assembly Cleaning

Remove

seal. Check

all

four

the

combined

as

detailed

and

Inspection -sub-section

the

damaged

that

sides

of

the the

under

seal is

flue

fan

seal

and

positioned

outlet.

and

collector

Section

17 -

5.

fit a replacement

evenly

hood

Routine

around

26. TO REPLACE THE PRESSURE GAUGE

(a)

Drain

down

the

(Drain

(b)

Remove

(c)

Unscrew

using a 15mm

(d) Fit a

jointing

(e)

Open

as necessary.

cock

Fig 43).

the

new

pressure

compound.

all

radiator

heating

appliance

pressure

open

valves

front

gauge

ended gauge.

and

hot

panel.

from

spanner.

Use a small

fill

the

system,

water

the

quantity

system.

heat

venting

bank

of

Fig.

45

TOP

UNION

ELBOW

27. TO REPLACE THE SEALED SYSTEM PRESSURE VESSEL

(a)

Remove screws

(b)

Remove

(c)

Drain

(Drain

(d)

Remove hex

(e)

Disconnect

valve.

Release

(f)

manifold

(g)

Release service

Remove

(h)

manifold ifold

(j)

Withdraw

attached Replace

flange

(k) Release

vessel tor

Remove 22mm

(m)

Reassemble the Ensure

NOTE:

the

burner

the

(Fig 1

).

the

front

down

the

cock

Fig 43).

the

head

block. (Fig 43).

pipe

system

An

inner

screws.

the

(Fig 43).

the

block. (Fig 32a).

the

gas

cock. (Fig 43).

the

flange

the

out

of

or

renew,

gasket

the

and

the

complete

the

remaining

connector

the

and

the

appliance

'0'

ring

manifold

kick

strip

by

panel.

heating

casing

pipe

M5

screws

union

M5

screws

the

underside

with

front

of

if

damaged,

connections

bank.

drain

half

the

for

and

by

Remove

controls

(Fig 32b).

pilot

two

line

four

to

valve,

the

on

reassembly.

union

heat

with

from

appliance

check

seal is recessed

block. Replace

releasing

and

hot

releasing

at

the

adaptor

securing

connection

securing

of

cables

the

appliance.

the

at

the

cock. (Fig 46).

of

the

base

of

the

in

reverse

water

and

operate

into

or

renew

the

water

the

burner

and

burner

the

short

%R

(%in

heat

order.

gas

the

underside

if

five

system.

four

and

the

at

the

gas

manifold

pressure

connec-

bank.

soundness.

correctly.

damaged.

M5

gas

burner

gas

burner

man-

line

BSP) x

Re-fill

of

38

28.

TO REPLACE PILOT VIEWING WINDOW

The pilot viewing window (Fig 32b) a viewing window needs replacing a complete inner casing front cover can Refer

to

(a)

Remove the inner casing front cover M5 screws. (Fig 32b).

(b)

Fit a new inner casing front cover.

(c)

Refit the front panel.

29.

TO REPLACE THE SAFETY VALVE

(a)

Remove the top cover (Section 3(a)).

(b)

Drain down the heating and hot water systems (Drain cock Fig 43).

(c)

Unscrew the safety valve from the connection on the internal expansion/cold feed pipe (Fig 47).

(d)

Fit a new safety valve. amount

(e)

Make sure the valve discharges into the tundish below.

(f)

Open necessary. The appliance vent

30. TO REPLACE THE DHW HIGH LIMIT THERMOSTAT

Refer

(a)

Remove the appliance front door, top cover, boiler front cover and facia.

(b)

Remove the pozidrive screw, attaching the bottom of the baffle plate behind the control panel to the top of the boiler. Remove the two plate. Lift the plate

(c)

Remove the clip from the end phial pocket.

(d)

Remove the thermostat phial from its socket and feed it out electrical box.

(e)

Pull off the two electrical connectors at the thermostat.

Polarity Remove the thermostat centre post fixing nut situated

under the

Ease the thermostat out of its locating hole.

be

Section

on

of the

obtained and fitted.

19

- Short Parts List.

of

jointing compound.

all

radiators

the heat bank. Check that

to

Figs 30 and

exposed

is

not important.

control panel.

and

40.

M5

hex. head screws behind the baffle

up

and out

hole at the left-hand side of the

is

not a serviceable item.

by

releasing the four

In

both instances use a small

fill

the

is

system,

fitted with

~he

of

the top

of

the overheat thermostat

an

automatic air

cap

is

loose.

of

the appliance.

venting

as

If

Fig. 46

EXPANSION VESSEL

(f)

Replace ensuring:-

(i)

The split

(ii) Any

surplus capillary tube

the control panel,

with a new

is

replaced.

in

SCHRAIDER

PRESSURE VALVE

COCK

DRAIN

UNION CONI\IECTION TO

EXPANSION VESSEL

thermostat

the space below the control panel.

in revE!rse

is

coiled neatly, OUTSIDE

order,

Fig. 47 Combined Feed and

INTERNAL EXPANSION

/FEED

PIPE

UNION

DHW FLOW

REGULATOR

COMBINED

AND VENT

FEED

PIPE

Vent

Pipe

SAFETY

CENTRAL

FLOW

CENTRAL HEATING RETURN

DOMESTIC HOT WATER FLOW

VALVE

HEATING

39

19.

SHORT

PARTS

LIST

Key

No.

166 378034 106 103 102 100 101

109

110 386778 131 104 371402 Pump Delay Timer Board 105 107 324978

f-c-

.

~6

t-c·

GCNo.

30 382849 Main Burner 32

382851

31

378742 Gas Valve 33 324984 34 381702 Pilot Injector 35 382448 Spark Electrode 36 324982 Electrode Lead

382854

395958

385482

384542 Suppressor

371531

368289 Relay Omron MY4

24

385883

108 394279

52

382897 Flow Regulator Type

51

324822 Flow Filter

54

324917

---------

55

371376 Pressure 174 386789 172 382883

37i.35o:2

19

-·

23 324949 1 ZBUNC191 22 371470

3

43 371472

371355

25

368144 Flange Sealing Washer 1 ZEGAS010

38 39 371473

324883

37

324820

50

Main Burner Injector

Pilot

Burner

Pump

Diverter Valve Heating

DHW Control Thermostat DHW Overheat Thermostat

High Limit Thermostat

3

Pos.ltion

Programmer (Optronal)

Electronic

Fan Sifan Ref. UP114741

Fan Pressure Switch

Auto

Air

Safety Valve Caleffi 3141 1

~xp~~-~~~~

lnsullation

-----

Collector Hood Seal

Fan Sealing Inner Casing Front Cover 1 Heat Exchanger Union Washers Supplied with items 1 Heat Exchanger 1 ZAGAS019

Burner Manifold Flange Gasket 1 ZEGAS140 Burner Manifold

Flow Regulator Union Washer 1 ZGWSH106

DHW

Hrgh

Description

Control

Thermostat

Switch

Sequence

Vent

Gauge

Board

E.

lime

Vessel

Combustion Chamber

Gasket

'0'

Ring Seal 1 ZDELE241

Lrmrt

Thermostat Ranco LM7 P5065 1 ZAMAJ134

Manufacturer's

Furigas 156.500.003

Furigas 515.001.000.4.5

Honeywell VR4601 PA2004 Honeywell Honeywell Honeywell

Vernitron

Grundfos 15·60 ACL 6798 Ranco CL6 Ranco CL6 Elmwood 2455RBU Ranco LM7 P8503 ITT TS121 P Arrow 2004E Worcester Heat Systems Pactrol 408401

Vernitron 22507/005

Dungs LGW.3A 1 Drg. No. 3/5211

Wika, 0·4 bar, 0·60 psi 1

Zilmet Type

0389 Ref. 45.004.108.005 Ref. 45.003.939.001

1100

P0128 P0147

541

Reference

Type 27

mm

06.

16·19

and

Qty WHS Part No.

~·s

1 ZAGAS069 1 ZAGAS076 1

ZAGAS133

1

ZBGAS040

1 ZBGAS045

1 ZBGAS050 1

ZBGAS033 1 ZAMAJ198 1 ZAMAJ116 1

ZAGAS008 1 ZAGAS207 1

ZAMAJ223 1

ZAMAJ132 1 ZDELE061

1 ZDELE237 1

ZAMAJ163 1 ZAGAS080 1

ZDELE183 1 ZAGAS055 1 ZAMAJ047 1

ZAGAS060 1 ZBUNC125 1 ZBUNC230 1

ZMMIS055

ZBUNC145

ZCVLV018 1 ZMMIS084 4 ZEINS055·7

1 ZEGAS170

SSA6252

ZGWSH118

2

40

24

172

.,

cp"

~

co

en

~

0

:l

"'0

I»

:l

0

r-

c;;-

-

ol:lo

...&

39

~

106

25

54

•

108 174 52 32 43 37

166

0

55

'

36

...

---

33

. 0

51

•

34 50 38

35

~

22

-e

u,

107

i6

105

110

•

~

&

'·

0 3

104

fj)

101

16-19

!If

CD

131

1

NOTE:

Preliminary electrical system checks to be carried out during a the breaking and remaking POLARITY;

before

20.

D:

RESISTANCE

replacing them.

FAULT

fault finding procedure. On completion

of

electrical connections, then the

TO

EARTH-

FINDING

SWITCH

ON

MAINS SET 3-POSITION PROGRAMMER POSITION.

WAIT 3 MINUTES. THERE A LIVE TERMINAL TERMINAL-STRIP

SWITCH THE TO FITTED THE ON, CH SUPPLY NOT

SWITCH THE TO WITH A PROGRAMMER CH SELECT IS THERE A LIVE SUPPLY TERMINALS

ON PROGRAMMER AVAILABLE AND WITH DOES THE HW SEQUENCE'

i e

TERMINAl 1 ONLY HW & CH

TERMINAl

SUPPLY

LON

3-POSITION

THE

HW

SETTING. ON

WITH A PROGRAMMER

HW

SELECT

OFF.

IS THERE A LIVE

TO

TERMINAL

TO

2'

3-POSITION

HW

& CH. ON

BUTTONS

1 &

MODELS

FITTED

PROGRAMME

ROTATE THE DIAL CLOCKWISE

THE

AID

PROGRAMMER

& CH IN THE CORRECT

HW

ONLY

SHOULD

1 & 2

as

SUPPLY

SWITCH

IIF FITTED)

TO

THE

ONL

Y7

YES

BUTTON

1 BUT

~

YES

UNITS

FITTED

SET

TO

2'

l

YES

I

WITH

SELECT EACH

OF A MUL

TIMETER

ENERGISE

ONLY

contained

MUST

OR

TO

OFF

IS

SWITCH

UNITS

SET

TO

SWITCH

HW

&

ON

A

IN

TURN

SELECT

in

the BGC

be repeated.

NOTE.

COMPONENT FOLLOWING ESSENTIAL WIRING CONTINUITY ROUTING

NOTE

THE

PUMP

WILL COMPLETE CYCLE THE OVER

RUN

TURNED

IS

CONTROL

THE

ON. ENSURE

NOT

DRY

IMMEDIATELY IS PUMP

Multimeter

of

checks-

ALWAYS

BEFORE

CHANGING

INDICATED

GUIDE

IT IS

THAT

THE

AND

15

MINUTES!

MAINS

CORRECT

SUPPLY

THAT

ASSOCIATED

THE

IS CHECKED FOR

OPERATE FOR ONE

Instructions Book are the first electrical checks

the Service Fault Finding task which has required

A: EARTH

CONTINUITY;

8: SHORT CIRCUIT;

check wiring continuity between components

ANY

IN THE

NO

OF

NO

·:

NO

-~

NO

. f REPLACE

f IS THERE A LIVE

I

TERMINALS7

r REPLACE THE 3-POSITION

OR

SUPPLY

YES

PROGRAMMER

l

~~6~ARC1JJtfRSITION

f REPLACE 3-POSITION

PROGRAMMER

SWITCH

It

SWITCH

PROGRAMMER

TO

OTHER

SWITCH

OR

NO

lMINAL

~-"'"

'""

rERNAL

WIRING

~"'

1

"""

I

OR

-1

I

'"~"

m

NO

'"'""

'""

T

C:

'"

I

l

~

3-POSITION

& CH OR

IF A PROGRAMMER

HW

BUTTONS

TO

AND

HEATING

TO

MAXIMUM.

RnAY

CIRCULATING

THE HOT

WATER

FULLY

UNTIL

THE

ROOM

THERMOSTAT,

MAXIMUM.

DIVERTING VALVE

YES

7'

tYES

A MAINS

SUPPLY

LIMIT THERMOSTAT'

YES

L-

YES

AND

ON. TURN

CONTACTS

YES

SWITCH THE TO

HW IS FITTED SET THE SELECT HOT WATER THERMOSTATS THE FOUR POLE

CLOSE'

DOES THE RUN7

TURN THERMOSTAT ANTI-CLOCKWISE TURN FITTED, TO WATER

IS THERE A LIVE SUPPLY TO TERMINAL

IS

THERE

THE

HIGH

SWITCH

CH

DO

PUMP

PRIORITY

IT CLICKS

DOES THE

OPENl

TO

BOTH

IF

CONTACTS

-

~IS

THERE A LIVE

TERMINAL

47

~REPLACE

HOT THERMOSTAT CONTACTS

CLOSE'

NO

IS THERE A LIVE SUPPLY TO TERMINAL

107

I

REPLACE

PUMP

DOES

CIRCULATING PUMP

NO

~~DO

THE RELAY

r REPLACE

WATER

THERMOSTAT

NO

, r

PRESS

ON

THERMOSTAT IS

--

--~-

-

NO

YES

NO

YES

NO

ON

HIGH

TO

BOTH

l

--

IS THERE A LIVE SUPPLY TERMINAL

r REPLACE

THERMOSTAT

CONTACTS

REPLACE

TERMINAL

r

CHECK

ROOM

CIRCUIT

. r REPLACE

LIMIT

CONTACTS?

----

SUPPLY

TO

NO NO

WATER

PRIORITY

DO THE RELAY

1

YES

NO

OVER

RUN

CIRCUIT RUNl

1YES

CONTACTS

OPEN7 IS THERE A LIVE

NO

PRIORITY

DOES VALVE OPEN7

tYES

RESET

BUTTON

THERE A LIVE

SUPPLY

YES

47

HOT

WATER

DO THE RELAY

CLOSE7

1

CIRCULATING

It

SUPPLY

87

THERMOSTAT

BETWEEN

~YES

HEATING

1

NO

-----~-

TO

LIMIT

YES

PUMP

TO

NO

FOR

TERMINALS 2 & 3

THERMOSTAT.

_ r

REPLACE THERMOSTAT

HIGH

1

YES YES

NO

I

YES

NO

1

LIMIT

REI>LACE RELAY

REPLACE

"

1

--

It

WATER DIVERTING

--

VALVE

l

I

42

~------~

I

i

I

I I

I

i

I I

I

i

I

AND

OF

7, 8

SUPPLY

9'

IS

THERE A

AFTER

SUPPLY

THE SCC

NO

AND

NO

PILOT

AT

DOES

FAN

RUN7

YES

REMOVE PILOT SOLENOID PLUG FROM SEQUENCE CONTROL P C.B. (TERMINALS IS

THERE A

MAINS

BETWEEN PINS 8

YES

REPLACE PILOT SOLENOID PLUG ONTO

PC.

B.

PINS

BETWEEN ELECTRODE

SPARK AND

PILOT'

YES

DOES PILOT

LIGHT'

YES

DOES

SPARK

CEASE

FLAME

IS

ESTABLISHED'

YES

IS

THERE A

MAINS

"'

10

TERMINAL BOARD

YES

TERMINAL

YES

NO

{t

STRIP I

l

I

REPLACE PRESSURE SWITCH THERE A

MAINS

AND

YES

SUPPLY BETWEEN

37

J.,

NO

PINS 1

REMOVE PLUG TO FAN FROM

I SEQUENCE CONTROL p C.B

(TERMINALS

1, 2 AND

MAINS

OF

THE

ON

3)

SUPPLY

AND

37

THE FAN

BOILER>

CHANGE FAN REPLACE COVER

IS

THERE A

BETWEEN PINS 1

P C.B

I'"~"""","'"""'""'"

REMOVE BOILER FRONT COVER IS THERE A MAINS

SUPPLy

IN THE TOP

~

NO

CHECK

PIPE

91

I

NO

I

CLEAN PILOT CHECK PILOT I

INJECTOR IS BLOCKED DOES LIGHT'

NO

CHECK LEAD INCORRECT CEASE7

NO

REPLACE SEQUENCE

CONTROL CIRCUIT BOARD

NOT

THE

PILOT

FOR

CONNECTIONS

YES

'I

CONNECTIONS COMBUSTION SWITCH ARE

ALL CONNECTIONS SECURE

WORK CLEAR>

YES~

CHANGE

PRESSURE

A MAINS

SUPPLY

YES~

DOES TRIGGER TUBE ON SEQUENCE CON TROL BOARD FLASH SECOND INTERVALS>

YES

t

CHECK

FOR

SHORT CIRCUIT OR

ELECTRODE. RECTIFY AS NECESSARY I

IS

THERE A SPARK BETWEEN ELECTRODE

AND

PILOT'

YES!.

NO

RESTRICTOR ON

I cou" "

THEN OPEN DOES PILOT

LOOSE ELECTRODE

OR

FITIING

DOES SPARK

l

BETWEEN FAN

CHAMBER

AND

SWITCH

IS

THERE

TO

7

PINS

8 AND 9

AT

APPROXIMATELY

ON

H T LEAD I

SUPPLY

OF

GAS TO THE

i '"""' " """' n

OF

INLET SIDE VALVE>

YES

1

GAS

"''

'"

m

TWO

FULL

LIGHT'

YES~

NO

CHECK FULLY GAS TURNS

I

PRESSURE AND

PIPE

I

~~

NO

THE

GAS

VALVE

TURNS

THAT

CLOSE

VALVE

DOES

t

YES

~

REPLACE SEQUENCE CONTROl

NO

1

NO

I

J

PILOT

JET

PILOT

RESTRICTOR

THEN

OPEN

SPARK

CEASE'

NO

IS

•I

REPLACE SEOUENCI

CONTROL BOARD

RECTIFY WIRING

I

FAULT

~

SUPPLY TO PINS

I ""'" ""'' "'">" '

CIRCUIT BOARD

8

NO

~

'I

REPLACE SEQUENCE CIRCUIT BOARD

NO

.I

RECTIFY

FAULT

NO

.J

REPLACE

I GAS VALVE

1

CLEAR

FULL

NO

ON

IS

TWO

t

I

AND

9'

"""

YES

I

CONTROl

I

REPLACE SEGUE CONTROL CIRCUI

YES

I

NCE

T BOARD

J

__

I

_j

CHECK

FOR

LOOSE

TERMINAL

ASSEMBLY

MAINS

VALVE'

CONNECTIONS

SUPPLY AT THE

~YES

FOUR PIN

IS

THERE A

MAINS

SUPPLY

AT

THE

SOLENOID

I

VALVE'

YES

MAIN

NO

PANEL IS

THERE A

SOLENOID

I

AT

STRIP IN CONTROL

MAIN

NO

.I

I RECTIFY WIRING

I

I I

I

SET 3-POSITION SWITCH PROGRAMMER SELECT BUTTONS A HANDMETER PRESSURE TEST PORT VALVESET 3 POSITION SWITCH PROGRAMMER SELECT BUTTONS THERMOSTAT CORRECTLY DOES

YES

SEE

MAIN

r-

I

DOES WITHOUT PILOT

MAIN

BOILING

STAYING

BURNER

ALIGHT'

YES

IS

FITED SET

TO

OFF.

TO

THE OUTLET

OF

FIG.

38

IS

FITTED SET

TO

ON. ENSURE ROOM

-IF

FITTED,

AND

CALLING

BURNER LIGHT>

STAY

ALIGHT

AND

WITH

THE

TO

OFF

HW

CONNECT

THE GAS

TO

HW & CH

IS

OPERATING

FOR

NO

OR

& CH

HEAT

IF

OR

IF

I

NO CIRCULATION HEATING SYSTEM. CHECK RADIATOR VALVES AND DOES ALIGHT'

AIR

MAIN

t

AROUND

HAS

BEEN VENTED

BURNER STAY

YES

ARE OPEN

NO

REPLACE CIRCULATING

1

PUMP

NO

~

REPLACE

GAS

V

""

J

I

.__-

- -

-----~------

43

--

-

-~---

--------~----

,------1

REFER

TO

FIGS 38 & 50 USING A PROCEDURE IN SECTION 14 & .!LOW! GAS PRESSURE

I

ln.Wg)

CAN PRESSURE

BE

SET>

YES

TO

ADJUST

m BAR

NO

TEST INCOMING SUPPLY PRESSURE TO APPLIANCE. IS THIS

HT

MINIMUM

THE

'------

RECTIFY SUPPLY FAULT CAN PRESSURE

I

OF

APPLIANCE>

BE

20

bar

(8

1n

-.-----...J

NO

1

SET

TO

l

YES

wg.)

AT

PES I REPLACE

ti

ADJUST

NO

GAS

VALVE

PRESSURE.

AND

I

1'

I

I I

I

I I

I

1'

I

I I I

I I

RESET HT & GAS PRESS SYSTEM REQUIREMENTS

I

CHECK HOT WATER (HIGH I GAS PRESSURE

:~

~~~S~~~~~fsR:0~;'BE

BAR

USING PROCEDURE

YES

CHECK ROOM THERMOSTAT

IS

CALLING

FOR

TAP

WAIT

3 MINUTES. USING

PROCEDURE IN SECTION 14 CHECK CHANGEOVER FROM HIGH PRESSURE.

IS

SATISFACTORY'

TURN CONTROLS CHECK ROOM THERMOSTAT FITTED IS CALLING

CHANGEOVER

YES

OFF

DHW TAPS SET

FOR

HEATING ONLY

REDUCE HEATING LOAD BOILER

TO RADIATORS DOES BURNER THERMOSTAT>

I

TO

SET

TO

m

IN

SECTION 14

IF

FOR

TWO

ON HEATING

YES

HEAT

TO

THREE

MAIN

FITIED

LOW GAS

IF

OF

HEAT TURN ON A DHW

CYCLE

0

i-N-

------------__;~1

NO NO

REPLACE GAS VALVE ·CHECK HIGH/LOW OPERATION

NO

DOES

MAIN

BURNER GO OUT

BEFORE

SYSTEM HAS REACHED CORRECT OPERATING TEMPERATURE>

l

YES

REPLACE

HIGH

LIMIT

SYSTEM

CYCLE

THERMOSTAT

NORMALLY'

I

DOES

1"'

~~~~~E

P~~~sV0'~~E

WITH

CONTROLS

SET

FOR

(LOW)

GAS

PRESSURE,

THERE

A LIVE

TERMINAL 8 OF

YES

IS

THERE

LIVE

SUPPLY

6

OF

TERMINAL TERMINAL STRIP

YES

IS THERE A

LIVE

GAS VALVE HIGH/LOW SOLENOID>

YES

NO

DHW

IS

SUPPLY

AT

THE

RELAY>

AT

THE

MAIN

SUPPLY AT

THE

l

DOES SYSTEM REACH I

EXCESSIVE TEMPERATURE

AND

MAIN

BURNER GO

REPLACE

HEATING

1

NO

!-------~~~

OUT'

THERMOSTAT

I

I REPLACE RELAY

il>l

CORRECT WIRING FAULT

.I

CORRECT WIRING FAULT

t

I

_j

I

SET CONTROLS

I

HOT WATER THERMOSTAT

g~g~ET,;;j~r'NA+~~

THERMOSTAT

FOR

DHW

ONLy

TURN I

TO

MAX

e~i~~r;.~RVALVE

IS

TURNED

TO

M<IXIMUM

NO

1---------------~l

~r;'~~CE

WATER DIVERTING

I

YES

'-----

------------

44

--

~--

--

----

-- --

----

--

,-

1

I

i

I I I

I I

I

AFTER APPROX. 10-20 MINUTES

DO

THE

BURNER TURN

YES

RELAY

AND

CONTACTS OPEN MAIN

OFF?

THE

o

P

DOES

THE

HOT WATER LIMIT

THERMOSTAT OPERATE

BY THE

THE

MAIN

OR

THE SYSTEM BOIL

MAIN

OUT

BUT

BURNER GO

THE

AND

HOT

-INDICATED BURNER GOING RELAY CONTACTS STAYING CLOSED'

DOES OUT

AND

IF

SO REPLACE BOTH WATER CONTROL WATER LIMIT STATS

~I

THE

HOT

THE HOT WATER HEAT

IS

ABOVE

EXCHANGER

L------,---____1

REPLACE HOT WATER LIMIT I

THERMOSTAT

eo•c

NO

I

YES

REPLACE HOT WATER

PRIORITY THERMOSTAT

I

i

I

DOES

THE

CIRCULATING

PUMP CONTINUE

FOR

APPROXIMATELY 5

MINUTES

AND

THEN STOP>

SET 3 POSITION SWITCH 'STAT-

IF

FITTED-

THERMOSTATS TO USERS REQUIREMENTS

CYCLE COMPLETE

1---------------~1

TO

RUN

YES

OR

PROGRAMMER, ROOM

AND

DHW/CH CONTROL

NO

REPLACE PUMP OVER-RUN

-~CIRCUIT

I

I I I

I

~__j

45

NOTES:

46

NOTES:

47

~.,

~ORCESTER

Bosch Group

Worcester Heal Systems Limited, Cotswold Way, Warndon, Worcester

Telephone- (0905)

754624

Fox· (0905)

754619

Telex-

337193

WR4

9SW

This booklet

ts

accurate at the

dale

of printing

All

goods sold are subject to our official Conditions of Sale, a copy of which

but

will

be

superseded

PUBLICATION ZKLIT824, ISSUE 2-JANUARY

and

should

be

of continued improvement.

disregarded

if

specifications

may

1994

and/or

appearances

be

obtained on applicatton

are changed in

the

interests

Worcester Bosch Highflow 3.5 RSF Installation And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual