Worcester Bosch Highflow 3.5 RSF Guida utente

....--

~

~ORCESTER--.

Highflow

3.5

RSF

ROOM

SEALED

FANNED

FLUE

MODEL

FLOOR STANDING COMBINATION BOILER FOR CENTRAL

HEATING

AND

MAINS

FED

DOMESTIC

HOT

WATER

INSTALLATION AND

SERVICING

INSTRUCTIONS

GC

NUMBER

41

311

40

BOILER OUTPUT

To

Hot Water

Maximum

23.4

kw

(80,000

Btu/h)

To

Central Heating

Minimum

8.8

kW (30,000

Btu/h)

Maximum

23.4

kW (80,000

Btu/h)

IMPORTANT:

THIS

APPLIANCE

IS

FOR

USE

WITH

NATURAL

GAS

ONLY

THESE

INSTRUCTIONS

APPLY

IN

THE

UK

ONLY

THESE

INSTRUCTIONS

ARE

TO

BE

LEFT

WITH

THE

USER

OR

AT

THE

GAS

METER

...__

_____

:::.

~

.rwoRCESTER

_____

...

Bosch

Group

CONTENTS

INSTALLATION

REGULATIONS

AND

TECHNICAL

DATA

Section

1

Section

2

Section

3

Section

4

Section

5

Section

6

Section

7

Section

8

Section

9

Section

9.1

Section

9.2

Section

9.3

Section

10

Section

11

Section

12

Section

13

Section

14

Section

15

Section

16

Section

17

Section

18

Section

19

Section

20

General

Information

Siting

the

Appliance

Removal

of

Cabinet

System

Considerations

Air

Supply

-

Horizontal

Flues

Terminal

Position

-

Horizontal

Flue

Air

Supply

-

Vertical

Flue

Connection

of

Primary

and

Secondary

Vertical

Flues

Installing

the

Appliance

-

General

Rear

Horizontal

Flue

Outlet

Vertical

Flue

Systems

Pre-plumbing

of

the

Appliance

Completion

of

the

Installation

Sealed

Primary

System

-

Open

Vent

Secondary

System

Open

Vent

Primary

System

~

Mains

Feed

Secondary

System

Mains

Feed

Domestic

Hot

Water

Supply

(Secondary)

Electrical

Commissioning

the

Appliance

System

Guidance

and

Bypass

Adjustment

Users

Instructions

Routine

Cleaning

and

Inspection

Replacement

of

Parts

Short

Parts

List

Fault

Finding

Chart

INSTALLATION REGULATIONS

The

installation

of

this

appliance

must

be

in

accordance

with

the relevant

requirements

of

the

Gas Safety

(Installation

and

Use)

Regulations,

local

Building

Regulations,

Building

Standards

(Scotland)

(Consolidation),

current

lEE

wiring

regulations

and

bye

laws

of

the

local

water

undertaking.

It

should

be in

accordance

with

the relevant

recommendations

of

the

following

British

Standards

and

Codes

of

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

BS

5546:1:1990,

BS

5440:1:1990,

BS 5440:2:1989 and BS 6891.

Gas Safety

(Installation

and Use)

Regulations

1984:

It

is

the

law

that

all

gas

appliances

are

installed

by

a

competent

person,

in

accordance

with

the

above

regulations. Failure

to

install

appliances

correctly

could

lead

to

prosecution.

It

is

in

your

interest, and

that

of

safety

to

ensure

compliance

with

the

law.

The

manufacturers

notes

must

not

be taken,

in

any

way, as

overriding

statutory

obligations.

TECHNICAL

DATA

NOTE: THE

DATA

PLATE

IS

POSITIONED INSIDE THE APPLIANCE

AT

THE FRONT LEFT

HAND

SIDE.

Table

1

NOMINAL

BOILER RATINGS (10

minutes

after

lighting)

BURNER SETTING

MODE

OUTPUT

INPUT PRESSURE GAS RATE

kW

(Btu/h)

kW

(Btu/h) m bar (in.

wg)

m3

/h

ift'ih

I

8.79 (30000) 12.0 (40955) 2.2 (0.88) 1.11 (39.4)

11.0 (37545) 14.7 (50170) 3.2 (1.28) 1.36 (48.3)

HEATING 13.0 1443701 17.1 (58360) 4.4 (1.76) 1.59 (56.2)

RANGE 15.0 151195) 19.6 (66555) 5.8 (2.32) 1.81 (64.0)

17.0 (58020) 21.9 (74745) 7.3 (2.92) 2.03 (71.9)

19.0 (64845) 24.2 (82595)

9.1

(3.64) 2.25 (79.5)

23.44 (80000) 29.3

(1

00000) 14.3 (5.72) 2.72 (96.2)

DOMESTIC 23.44 (80000) 29.3

(1

00000) 14.3 (5.72) 2.72 (96.2)

HOT WATER

Note:

The

pressure

test

point

is

located

on

the

gas

valve

(See

fig.

31a).

2

Table 2

SPECIFICA

nONS

HEATING FLOW

28mm

COPPER

TUBE

HEATING RETURN

28mm

COPPER

TUBE

SAFETY VALVE

22mm

COPPER

TUBE

COLD

FEED

22mm

COPPER

TUBE

COLD WATER

MAINS

IN

15mm

COMPRESSION -SUPPLIED

DOMESTIC WATER OUT

22mm

COPPER

TUBE

GAS INLET

22mm

COPPER

TUBE

HEIGHT

860mm

(33.9in)

WIDTH

550mm

(21.6inl

DEPTH

600mm

(23.6in)

WEIGHT 95kg (2101b)

empty-

147kg (3241b) full

PRIMARY CAPACITY 48 litres (10.6 gal)

*MAXIMUM

STATIC HEAD

25m

(81ft.)

*MINIMUM

STATIC HEAD 1000mm (39in)

CIRCULATING PUMP

Grundfos

15-60

EXPANSION VESSEL 12

litres

charged

0.5

bar

OUTPUT

TO

HEATING

MAXIMUM

23.4kW (80,000 Btu/h)

OUTPUT

TO

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

CH

CONTROL

THERMOSTAT-

MAX.

TEMPERATURE

Nominally

82°C

(180°F)

DOMESTIC HOT WATER FLOW

RATE

(35°C

RISE)

Nominally

9.6

litres/min

+

15%

(2.1

gal/min)

MAXIMUM

DOMESTIC HOT WATER FLOW RATE

Nominally

15

litres/min

(3.3

gal/min)

±15%

*

Appliance

static

heads

are

measured

from

the top

of

the

casing

to

the

highest

point

of

the

system

(See

Fig_s.

24.

and

25)

Table 3

HORIZONTAL VERTICAL

FLUE

DETAILS-

See Notes

Below

REAR FLUE PRIMARY FLUE

WALL OR

CEILING-

HOLE DIAMETER FOR AIR DUCT 125mm (Sin) 125mm (Sin)

WALL HOLE DIAMETER FOR SEALING RING 150mm (6in)

MINIMUM FLUE

LENGTH-

STANDARD FLUE KIT 100mm (4in) 1557mm (61.3in)

MAXIMUM FLUE

LENGTH-

STANDARD FLUE KIT 1

OOOmm

(39in) 2000mm (73in)

FLUE LENGTHS WITH EXTENSION KIT 1

001

to 2000mm

2001

to

3000mm

(39

to

73in) (79

to

118in)

If

a

flue

extension

is

required

(See

Section

9)

it

may

be

obtained

from

Worcester

Heat

Systems

Ltd. ONE

EXTENSION

FLUE

KIT ONLY

MAY

BE

USED

PER

APPLIANCE. Part No. ZAGAS066

Table 4

AVAILABLE PUMP HEADS

HEATING OUTPUT HEAD MIN. FLOW RATE OPTIMUM

kW Btu/h METRES

FEET

LITRES/MIN.

GALUMIN.

TEMPERATURE

RISE

8.8 (30,000)

5.1

16.6

8.41

1.89

11

(37,500) 4.7 15.5

10.51

2.36

13

(44,350) 4.3

14.1

12.42 2.79

15°C

between

15

(51,200) 3.8 12.6 14.33 3.22

heating

flow

and

return

17

(58,000) 3.3 10.9 16.24 3.65

19

(64,800) 2.2 7.2 18.15 4.08

23.4 (80,000) 1.5 5.0 22.35 5.02

3

1.

GENERAL

INFORMATION

IMPORTANT:

Although

the

appliance

includes

the

facility

to

instal

a

sealed

primary

water

system

and

feed

the

sec-

ondary

system

via

the

mains

supply,

only

one

of

these

can be

used,

i.e.

the

system

arrangement

must

be

one

of

the

following:

(i) Sealed

primary

and

open

vented

(i.e.

cistern

feed)

secondary

(Section

10)

or

(ii)

Open

vented

primary

and

mains

feed

secondary

(Section

11)

or

(iii)

Open

vented

primary

and

open

vented

(i.e.

cistern

feed)

secondary.

FOR FURTHER ADVICE

CONTACT

WORCESTER

HEAT

SYSTEMS

LTD.

1.

HIGHFLOW

3.5 RSF INCORPORATES

(a)

An

induced

draught

fan, a

low

thermal

capacity

heat

exchanger

having

a

maximum

heat

output

of

23.4kW (80000 Btu/h).

(b)

Either

a

horizontal

(rear

outlet)

or

vertical

fanned

flue

system

-to

order.

(c) A

standard

duct

kit

for

horizontal

flue

lengths

from

100mm

{4in)

to

1000mm

{39in).

(An

extension

duct

kit

from

1001

mm

(39in)

to

2000mm

{79in)

maximum

length

is

available

as an

option).

A

standard

duct

kit

for

vertical

flues,

complete

with

diverter

intended

for

installation

within

a

roof

space.

The

kit

will

enable

the

diverter

to

be

installed

be~

tween

1557 (61.3in)

and

2000mm

(79in)

above

the

appliance

top

outlet.

(An

extension

duct

kit

from

2001mm

(59in)

to

3000mm

{118in) is

available

as an

option).

(d) A

heatbank

having

a

nominal

capacity

of

45

litres

(10

gallons)

of

circulating

primary

hot

water

posi-

tioned

inside

the

appliance.

A

copper

finned

water

to

water

heat-exchanger

is

fitted

into

the

heatbank.

Secondary

supply

domestic

hot

water

passes

through

the

heat

exchanger.

{e) A

diverter

valve

to

direct

the

boiler

output

either

to

domestic

hot

water

or

central

heating

as

required.

(f) A

circulating

pump.

(g) A

multifunctional

HIGH/LOW

gas

valve

and

elec-

tronic

control

system

to

control

individually

the

domestic

hot

water

and

central

heating.

The

system

provides

automatic

ignition.

(h)

Boiler

and

hot

water

temperature

control

thermo-

stats

providing

control

for

central

heating

and

dom-

estic

hot

water.

(j)

A User/s

Operating

Switch

for

selection

of

water

only

or

heating

and

water.

A

programmer

kit is

available

as an

optional

extra.

(k)

An

expansion

vessel,

pressure

gauge,

pressure

relief

valve

and

auto

air

vent

to

enable

the

primary

circuit

to

be

connected

to

a sealed

water

system.

{I)

An

electronic

pump

delay

control

board

which

en-

ables

the

pump

to

run

on

for

a

period

of

about

5

min-

utes

after

each

operating

cycle.

2.

INSTALLATION

WARNING:

GREAT CARE

MUST

BE

TAKEN

TO

ENSURE

THAT

NO

FOREIGN

MATTER

IS

LEFT IN THE

WATER

SYSTEM. THIS

COULD

CAUSE

DAMAGE

TO

THE

APPLIANCE.

3.

NATURAL

GAS

SUPPLY

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

supply pipes

must

be capable of delivering this quantity of

gas

in

addition to the

demand

from any other appliances

in tho house.

The

meter

outlet governor

must

ensure a

nominal pressure of 20

mbar

(Bin wg) at the appliance,

equivalent to a pressure of about 18:5-19

mbar

at the gas

valve.

The

complete

installation,

mcluding

the

meter,

should be inspected and tested for soundness and purged

in

accordance with the recommendations of BS 6891.

4

4. ELECTRICAL SUPPLY

Mains

supply

240

V,

........

50 Hz, 160

watts

fused

at 3A.

See

Section

13.

The

length

of

supply

cable

provided

with

the

appliance

is

rated

at a

temperature

of

aooc

continuous.

5. OPEN

VENTED

SYSTEM

The

appliance

is

supplied

ready

for

connection

to

a

sealed

water

system.

An

open

vented

system

can

be

used

by

carefully

removing

the

safety

valve

and

seal-

ing

its

connection.

See

Section

11. Care

should

be

taken

not

to

distort

the

pipe.

6.

CONTROLS

All

controls

included

with

the

appliance

are

specified

in

the

'Short

List

of

Parts'

included

in

this

leaflet.

There

is

provision

for

a

room

thermostat

and

frost

thermostat

to

be

fitted

to

the

appliance.

See

Section

13.

Thermostatic

radiator

valves

can be

used

in

the

system;

however,

a

suitable

by-pass

is

essential

with

this

type

of

control.

See

Section

15.

7.

DRAINAGE

A

drain

cock

is

fitted

in

the

pipe

connecting

thE!

primary

heat

bank

to

the

sealed

system

expansion

vessel

to

drain

water

from

the

boiler

and

the

heat

bank. (Fig. 46)

8.

PACKAGING

The

appliance

is

despatched

in

one

package. A sep-

arate

package

contains

either

the

standard

horizontal

or

vertical

flue

kit. Each kit

includes

either

a

balanced

flue

terminal

(horizontal

flue)

or

diverter

(vertical

flue)

together

with

the

necessary

duct

work,

sealin~1

materials,

etc.

2.

SITING

THE

APPLIANCE

(Refer also to sections

5,

6,

7 and 8).

1. The appliance is floor standing and the floor

must

be firm

and level.

2.

The

following

clearances

must

be

left

to

allow

for

servicing and ventilation:

(a) Above the appliance: Servicing 450

mm

(18 in.)

Ventilation 5 mm (0.2 in.)

(b) In front of the appliance: Servicing 600

mm

(24 in.)

Ventilation 75

mm

(3 in.)

(c) Left and right-hand side: Servicing 20

mm

(0.8 in.)

Ventilation 20 mm (0.8 in.)

NOTE:

Care

must

be

taken

to

ensure

adequate

space

is

available

at

either

side

for

installing

the

boiler.

See Sec-

tion

9.

3.

The

chosen

position

must

allow

the

provision

of

a

satisfactory

balanced

flue

termination.

See

Section

6,

if

a

horizontal

flue

system

is

to

be

used

OR

4.

The

chosen

position

must

allow

the

provision

of

a

satisfactory

secondary

flue

terminal

discharge

in

a

down

draught

free

zone. See

Section

8,

if

a

vertical

flue

system

is

to

be used.

NOTE:

If

the

appliance

is

to

be

fitted

in

a

timber

framed

building

it

should

be

fitted

in

accordance

with

the

British

Gas

publication

"Guide

for

Gas

Installation

in

Timber

Framed

Housing"

Ref

DM2.

If

in

doubt

advice

must

b~3

sought

from

the

local

Region

of

British

Gas.

3.

REMOVAL

OF

FACIA

PANEL

AND

CABINET

See Fig.

1.

NOTE:

It is

necessary

to

remove

the

cabinet

top

cover,

front

cover,

and

may

be

necessary

to

remove

the

facia

panel,

left

and

right

hand

side

panels

and

lower

grille

to

aid

installation.

Fig. 1

Cabinet

-

Control

Panel

and

Facia Fixing

Screws

A

A TOP

COVER

RETAINING LUGS

B TOP

COVER

FIXING BOLT

c FACIA FIXING SCREWS

D DHW AND

CH

THERMOSTAT

MOUNTING

BRACKET FIXING SCREWS

E CONTROL PANEL FIXING SCREWS

F CONTROL PANEL SUPPORT BRACKET

AND SCREW

G

LEFT

HAND SIDE PANEL FIXING SCREWS

H SIDE PANEL BRACKET FIXING SCREWS

J RIGHT HAND SIDE PANEL FIXING SCREWS

K LOWER FRONT GRILL

KICKSTRIP FIXING SCREWS

L FRONT COVER {NO FASTENINGS)

""

(a)

Remove

the

cabinet

front

cover

by

pulling

firmly

at

the

base

and

lifting

upwards

and

outwards.

Remove

the

cabinet

top

cover

by

slackening

com-

pletely

the

bolt

'B'

retaining

the

front

of

the

top

cover.

See

Fig.

1.

(b)

Pull

up

the

front

edge

of

the

cover

sharply

to

disengage

the

fasteners.

Draw

the

cover

forward

enough

to

disengage

it

at

the

rear

and

lift

clear.

(c)

Undo

the

five

screws

'K'

holding

the

lower

front

grille

kick

strip.

(d) Pull

off

the

two

thermostat

knobs

and

remove

the

five

screws

'C';

two

securing

the

ends

of

the

facia

to

the

side

panels

and

three

underneath

the

facia,

fixing

it

to

the

base

of

the

control

panel.

Pull

the

facia

forward

until

it

clears

the

side

panels.

The

facia

will

come

away

complete

with

three

position

switch

or

programmer,

if

fitted.

Support

the

facia

having

drawn

it

forward

enough

to

gain

access

to

the

plug

in

terminal

rail

positioned

behind

and

to

the

right

of

the

heating

thermostat.

The

terminal

rail

is

numbered

14

to

17

inclusive.

Separate

the

two

halves

of

the

terminal

rail,

enabling

the

facia

to

be

removed

completely.

(Fig. 37)

(e)

Remove

the

two

remaining

posidrive

screws

'C'

retaining

the

top

of

the

left

hand

side

panel

and

the

two

M5

slotted

head

screws

and

single

posidrive

screw

retaining

the

top

of

the

right

hand

side

panel

'J'.

Draw

the

side

panels

forward

and

lift

out.

NOTE:

The

control

panel

is

supported

in

position

by

a

single

posidrive

screw

'F'. (See Fig. 1).

This

is

intended

to

hold

the

panel

during

installation

only

and

no

undue

strain

should

be

placed

on

the

panel.

4.

SYSTEM

CONSIDERATIONS

(a)

The

appliance

includes

a

pump

and

no

other

circulating

pump

is

required.

When

fitting

a

room

or

frost

thermostat,

refer

to

Section

13,

Electrical.

The

appliance

will

operate

satisfactorily

on

a

two

pipe

small

bore

or

micro-bore

system.

5

J,C

c L

K

(b)

The

heatbank

contains

a

finned

copper

heat

exchanger

which

provides

domestic

hot

water.

A

control

system

is

incorporated

that

gives

priority

to

the

domestic

hot

water

and

the

central

heating

will

be

turned

off

when

a

demand

for

hot

water

is

made.

For

large

quantities

of

hot

water

the

control

thermostat

should

be

set

at

maximum

and

after

use, a

few

minutes

may

be

required

to

re-heat

the

heatbank.

The

central

heating

will

remain

off

during

this

period.

IT

IS ESSENTIAL TO FIT A BYPASS TO ALL

SYSTEMS.

5.

AIR

SUPPLY

HORIZONTAL

FLUE

1.

The

room

in

which

the

appliance

is

installed

does

not

require

a

purpose

air

vent.

2.

If

the

appliance

is

installed

in

a

cupboard

or

compartment,

permanent

air

vents

are

required

in

the

cupboard

or

compartment,

one

at

high

level,

and

one

at

low

level,

either

direct

to

outside

air

or

to

a

room.

Both

high

and

low

level

air

vents

must

communicate

with

the

same

room

or

must

both

be

on

the

same

wall

to

outside

air.

The

minimum

effective

areas

required

are

given

in

Table

5.

Table

5 COOLING AIR REQUIREMENTS

HORIZONTAL

AND

VERTICAL FLUE SYSTEMS

Position

of

Air

from

Air direct

Air

Vents

room

from

outside

High

Level

264cm

2

132cm

2

{41

in

7)

{20.5in

2)

Low

Level

264cm

7

132cm

2

(41

in2)

(20.5in

7)

6.

FLUE

TERMINAL

POSITION-

HORIZONTAL

FLUE

IMPORTANT

1.

Flue length. See

note

in

Section

1,

General

Informa-

tion,

regarding

standard

flue

assembly

and

extension

flue.

2. The flue must be installed in accordance

with

the

recommendations

of

BS

5440:Part

1.

Minimum

siting

dimensions

for

positioning

the

balanced

flue

terminal:

TERMINAL

POSITION (See Fig.

2)

MIN

DISTANCE

A-

Directly

below

an

open

able

window

or

other

opening,

e.g.

air

brick

300mm

(12in)

B-

Below

gutters,

soil

pipes

or

drain

pipes

75mm

(3inl

c-

Below

eaves

200mm

(Sin)

D-

Below

balconies

or

car

port

roof

200mm

(Bin)

E-

From

vertical

drain

pipes

and

soil

pipes

75mm

(3in)

F -

From

internal

or

external

corners

300mm

(12in)

G -

Above

ground,

roof

or

balcony

level

300mm

(12in)

H-

From

a

surface

facing

a

terminal

600mm

(24in)

1-

From

a

terminal

facing

a

terminal

1200mm

(47inl

J -

From

an

opening

in

a

car

port

(e.g.

door,

window)

into

dwelling

1200mm

(47in)

K-

Vertically

from

a

terminal

on

the

same

wall

1500mm

(59in)

L -

Horizontally

from

a

terminal

on

the

same

wall

300mm

(12inl

GENERAL NOTES

1.

The

terminal

must

be

positioned

such

that

the

com-

bustion

products

can

disperse

freely

at all

times.

2. In

certain

weather

conditions

a

terminal

may

steam

and

positions

where

this

could

cause

a

nuisance

should

be

avoided.

3.

If

the

terminal

is

fitted

within

850mm

of

a

plastic

gutter

or

within

450mm

of

painted

eaves, an

alumi-

nium

shield

of

at

least

750mm

long

should

be

fitted

to

the

underside

of

the

gutter

or

painted

surface

(Dimensions

8

and

C in Fig. 2).

4.

If

a

terminal

is

fitted

less

than

2

metres

(78.6in)

above

a

surface

to

which

people

have

access

then

a

suitable

guard

must

be

provided.

A

terminal

protect-

ive

guard

is

available

from:

Tower

Flue

Components

Limited,

vale

Rise,

Tonbridge,

TN9

1TB.

Terminal

Guard

Reference:

GC

393

553-

Type

K2.

The

terminal

guard

must

be

securely

fixed

to

the

wall

using

the

three

brackets

provided,

suitable

plugs

and

corrosion

resistant

screws.

The

guard

must

be

sym-

metrically

positioned

about

the

terminal

assembly

and

spaced

such

that

there

is a

gap

of

50mm

min-

imum

between

the

end

of

the

terminal

and

the

guard.

5.

The

air

inlet/products

outlet

duct

and

the

terminal

of

the

boiler

must

not

be

closer

than

50mm

(2 in)

to

combustible

material.

Detail

recommendations

on

protection

of

combustible

material

are

given

in BS

5440:1

1990,

sub-section

3.3

IMPORTANT

It is

absolutely

ESSENTIAL

to

ensure,

in

practice,

products

of

combustion

discharging

from

the

terminal

cannot

re-enter

the

building

or

any

other

adjacent

building

through

ventilators,

windows,

doors,

other

sources

of

natural

air

infiltration

or

for-

ced

ventilation/air

conditioning.

If

this

eventuality

should

occur,

the

appliance

MUST

be

turned

off

immediately

and

the

problem

rectified.

6

7.

AIR

SUPPLY

VERTICAL

FLUES

1.

The

room

in

which

the

appliance

is

installed

does

not

require

a

purpose

air

vent.

2.

If

the

appliance

is

installed

in

a

cupboard

or

compartment,

permanent

air

vents

are

required

in

the

cupboard

or

compartment,

one

at

high

level,

and

one

at

low

level,

either

direct

to

outside

air

or

to

a

room.

Both

high

and

low

level

air

vents

must

com-

municate

with

the

same

room

or

must

both

be

on

the

same

wall

to

outside

air.

The

minimum

effective

areas

required

are

given

in

Table

5,

COOLING AIR

REQUIREMENTS,

Section

5.

3.

ALL

installations

must

be

provided

with

purpose

designed

air

vents

in

the

roof

space,

communicating

direct

with

outside

air.

THE

MINIMUM

EFFECTIVE AREA REQUIRED

FOR

AIR

VENTS WITHIN A ROOF SPACE

IS

516cm

2 (80in2).

4.

The

roof

space

containing

the

diverter

must

be

sealed

off

completely

from:-

(a)

the

room,

cupboard

or

compartment

in

which

the

appliance

is

installed

and

(b)

any

other

room.

8.

CONNECTION

OF

PRIMARY

AND

SECONDARY

VERTICAL

FLUES

The

components

up

to

and

including

the

draught

diverter

are

supplied

and

these

must

be

installed

vertically

above

the

top

boiler

flue

outlet,

in

accordance

with

the

dim-

ensions

shown

in Fig. 3.

Note

that

the

draught

diverter

must

be

positioned

such

that

it

will

not

be

obstructed

by

such

as

loft

insulation.

A

secondary

flue

must

be

fitted

to

the

top

of

the

draught

diverter.

This

component

will

accept

flue

pipe

to

BS

715

size

125mm

(5in).

If

flue

pipe

to

BS 4543 is

used,

then

an

adaptor

will

need

to

be

fitted,

but

the

nominal

internal

diameter

must

not

be

decreased.

The

installation

of

the

complete

flue

system

must

be

in

accordance

with

BS

5440:1.

The

secondary

flue

system

must

be

adequately

sup-

ported

and

the

exit

from

the

roof

space

water

proofed.

Horizontal

runs

and

bends

should

ideally

be

avoided,

but

at

least

minimised,

and

a

spillage

test

must

be

carried

out

in

accordance

with

BS 5440:1. Fig. 3

shows

an

ap-

propriate

point

at

which

to

apply

the

test.

No

part

of

the

flue

system

shall

be

within

25mm

(1.0in)

of

combustible

material.

Table

7

Max.

secondary

flue

length

Max

secondary

flue

length

if

set

to

minimum

CH

input

if

set

to

maximum

CH

input

6m

(20ft)

1Om

(33ft)

The

flue

lengths

recommended

above

are

intended

to

en-

sure

that

condensate

does

not

form

in

the

secondary

flue

system

when

the

appliance

operates

under

all

approved

operating

conditions.

NOTE:

The

permanent,

purpose

designed

ventilation

openings

required

within

the

roof

space,

the

openings

within

the

diverter

and

any

compartment

ventilation

-

if

applicable-

MUST

NOT

BECOME BLOCKED.

The

user

MUST

be

instructed

not

to

store

items

within

the

roof

space

which

may

cause

an

obstruction,

or

in

the

compartment

-

if

applicable.

A

space

of

at

least

250mm

(10in)

radius

shall

be

provided

around

the

draught

diverter

with

no

obstructions

(Fig. 3).

Fig. 2 Siting of terminal

Horizontal Flue

A'

/

j '

-'l

..

GJ

~

Dj

'

:.Ji

, , I I

l]

A

I

~

BC~

'

L'hl

IK

•

v .

IK

!

~

I I

F'

/

,,

llF

~HI'

J

, I ' '

I.

I \

~J

'j

F

r·E

Fig. 3 Position of Vertical Primary

Flue and Secondary Flue

See also Fig. 17

TERMINAL

(NOT

SUPPLIED)

.•

TWIN

WALL

SEC. FLUE

-------+

IS

RECOMMENDED

DRAUGHT

T

DIVERTER

WITH

125mm-------l-·f"=Y

(5in) SOCKET OUTLET

~

CLEAR SPACE

250mm

(10in I

RADIUS

AROUND

··1-.,+-~

DIVERTER WITH

NO

..

. M .

OBSTRUCTIONS

STANDARD

FLUE KIT

MINIMUM

HEIGHT H

1557mm

(61.3in)

MAXIMUM

HEIGHT H

2000mm

(79in)

WITH EXTENSION

KIT

MAXIMUM

HEIGHT

H

~

3000mm

(118in)

BOTTOM

OF FLUE OUTLET

SOCKET

H

45mm:

(1.8in)

1;

l_

G

GENERAL GUIDANCE · SITING OF

VERTICAL FLUE

TERMINAL

CHIMNEY

ON

RIDGE

NOT

ON

RIDGE

PITCH

Dim.

Y

1m

(3.3ft)

EXCEEDING 30°

AT

OR

ABOVE ROOF

ABOVE INTERSECTION

PITCH

NOT

RIDGE Dim Y

250mm

(lOin)

EXCEEDING 30° LEVEL ABOVE ROOF

INTERSECTION

NOTE: A spillage test must be carried out at the

diverter HERE,

in

accordance with BS5440:1.

ROOF SPACE VENTILATED

TO

OUTSIDE AIR SECTION 7.3

CEILING FLUE SEALING PLATE

860mm

(33.9in)

7

9.0

INSTALLING

THE

APPLIANCE

GENERAL

If

a

HORIZONTAL

FLUE is

to

be

installed

refer

to

Sections

2,

5,

6,

9.1

and

9.3:

also

Figs. 2

and

4.

If

a VERTICAL FLUE is

to

be

installed

refer

to

Sections

2,

7,

8,

9.2

and

9.3;

also

Fig.

3.

NOTE:

MORE

THAN

ONE PERSON

MAY

BE

REQUIRED

TO

INSTAL

THE APPLIANCE.

The

space

required

for

installation

is

50mm

(2in)

at

the

left

hand

side

and

150mm

(6in) at

the

right

hand

side.

A

description

given

in

Section

9.3

covers

one

method

of

installation.

If

connections

are

made

in

a

different

way

then

the

space

required

for

installation

may

be

greater.

In

some

circumstances

when

installing

the

appliance,

particularly

where

minimum

clearances

for

access

and

servicing

have

been

used,

it

may

be

found

necessary

to

pre-plumb

the

appliance

and

fit

unions

and

stub

pipes,

(Fig

5)

to

the

boiler

pipework

before

moving

it

into

posi-

tion.

If

so

refer

to

Section

9.3

and

make

the

connections

before

assembling

the

flue

system.

Check

to

determine

whether

or

not

an

extension

kit is

required.

Refer

to

Sec-

tion

1(c)

and

Section

2.

A

knock-out

panel

is

provided

in

the

cabinet

top

panel

to

facilitate

vertical

pipe

connections.

Compression

fittings

may

be

used

on

all

water

con-

nections

to

allow

for

the

fitting

of

the

boiler

and

servic-

ing.

1.

Unpack

the

appliance.

2.

Unpack

the

standard

flue

kit

and

flue

extension

kit

(if

required)

and

check

the

contents

against

the

en-

dosed

check list.

Ensure

all

cardboard

packing

in

the

standard

flue

assembly

and

flue

extension

is re-

moved.

3.

Remove

the

top

cover

and

the

front

panel

from

the

cabinet

as

described

in

Section

3.

4.

The

boiler

is

supplied

suitable

for

a

horizontal

rear

flue

outlet

configuration;

the

vertical

outlets

being

sealed

off

with

blanking

plates.

If

a

vertical

flue

is re-

quired

refer

to

Figs 6

and

7.

To

gain

access

to

the

top

flue

outlet

cover,

first

re-

move

the

access

cover.

Fig.

6.

Fig. 4 Wall

preparation

·

Rear

outlet

Dimensions

mm

(in)

-1{~~

5

)r

1----

600 {23.6)

~

.L~

1:1.

r-

-,

I

r~~-

I

' ' '

)

~----~

.,(---

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

~

,.-t..""_

!.._-----

--

- -

~

(a)

Remove

the

top

air

duct

and

flue

duct

blanking

plates.

(b) Run a

bead

of

silicone

sealan1

around

the

inside

of

the

rear

flue

duct

and

air

duct

sockets.

(c) Fit

the

blanking

plate

into

the

rear

flue

outlet

socket,

push

fully

home

and

tighten

the

clamping

screw,

working

through

the

top

air

duct

socket

opening.

(d) Fit

the

rear

air

duct

socket

blanking

plate,

push

it

fully

into

the

socket

and

tighten

the

clamping

screw.

NOTE:

THE ACCESS

PANEL

MUST

BE

REPLACED

WHEN

THE FLUE

SYSTEM

IS

FITTED.

REFER

TO

SECTION 9.2a

{STANDARD

FLUE KIT)

OR

9.2b

{EXTENSION

KIT)

Subsection

3{a).

9.1.

REAR

HORIZONTAL

FLUE

1. Take

account

of

the

requirements

under

Section

2 -

Siting

the

appliance.

Refer

to

page

1

and

Fig

4.

Mark

the

flue

position

re-

quired

on

the

wall.

Cut

a

hole

in

the

wall

125mm

(5in)

diameter.

NOTE:

If

a

core

boring

tool

is

not

used

and

the

hole

is

made

oversize,

it

must

be

reduced

to

130mm

max-

imum

diameter

and

the

inner

skin

of

the

brickwork

made

good

before

the

appliance

is

installed

(Sec-

tions

9.1a; 9.1b; 9.1c).

2.

Determine

the

flue

length

by

referring

to

the

app-

ropriate

section

below,

which

details

the

correct

flue/

boiler

assembly

procedure.

Section

9.1a.

9.1b.

9.1

c.

Length

L

100mm-1000mm

(4in-39.4in)

1001

mm-1200mm

(39.4in-47.2in)

1201

mm-2000mm

(47.2in-78.7in)

NOTE:

REFER

TO

SECTION 9.3. COMPLETE THIS PART

OF THE

INSTALLATION

AS

NECESSARY BEFORE

ASSEMBLING

THE REQUIRED FLUE

ARRANGEMENT.

TOP AIR

DUCT

SOCKET

{DEPTH

18mm

{0.7in)

HOLE

CUT

THROUGH

WALL

TO ACCEPT REAR AIR

DUCT

WALL

THICKNESS TO

INCLUDE

ANY

SURFACE

FINISH, INSIDE

OR

OUTSIDE

REAR AIR

DUCT

SOCKET

{DEPTH

18mm

{0.7in)

INSIDE

PLASTER

DIMENSIONS

ON

PAGE 1

MAY

VARY

DEPENDING

ON

WHETHER

ANY

FLOOR COVERING IS

REMOVED

AND/OR

INSULATING

SHEET IS PLACED BETWEEN THE

APPLIANCE

AND

THE FLOOR

FLOOR LEVEL

8

OUTSIDE

RENDERING

IF

APPLIED

Fig. 5 Rear View of Boiler Pipework and Flue

Connections

NOTE: ALL DIMENSIONS ARE NOMINAL mm (in)

A CENTRAL HEATING RETURN (28mm)

B SAFETY VALVE (22mm)

C GAS INLET (22mm)

D DOMESTIC COLD WATER

IN-

R'h ('/,in BSP)

E DOMESTIC HOT WATER OUT (22mm)

F CENTRAL HEATING FLOW (28mm)

G VENT AND FEED (22mm)

H REAR FLUE CONNECTION (Centrelines)

=

I

[c

r--·

r

--~

r--:_:

I

~

~f

-:-·.

~

•

---

I

~..,

H 377mm

(14.81n)

___,

--550mm

{21.6in)--

-1

G & B200mm (7.9in)

D

170mm

(6_7in)

E 135mm

(5.3in)

F 90mm

(3.5~n}

A 60mm (2.4in)

mn

~-g-~

.£

:s

cr>LOcn~rn

<Drnoc<Jc<J

2.!-~~~'22.

E E E E E

N 0

lO

o o

<r>mro~<D

<Dr-r-roro

Fig. 7 Flue/Air Duct Socket Clamping Screws

NOTE: A SIMILAR METHOD

IS USED TO CLAMP THE

REAR AIR DUCT.

ACCESS TO THE SCREW

IS

FROM THE TOP (FIG

6)

VERTICAL AIR DUCT

CLAMPING SCREW

_.----

VERTICAL AIR

__

_;;;____ DUCT SOCKET

REAR

FLUE DUCT

CLAMPING SCREW

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

FLUE DUCT HOUSING

REAR

FLUE DUCT BLANKING

PLATE POSITION

9

APPLY SEALANT

AROUND

INSIDE

OF

FLUE

AND

AIR DUCT SOCKETS

tr

REAR

AIR DUCT

BLANKING PLATE

POSITION

I

9.1

a BOILER FLUE

ASSEMBLY

REAR

OUTLET

100mm-1000mm

(4in-39.4in}

NOTE:

An

extension

kit

is

NOT

required.

1.

Cut

the

air

duct

to

length

as

follows:-

(a)

Measure

the

wall

thickness

Land

add

28mm

(1.1in).

(Fig 4, 8

and

15).

This

is

the

overall

length

of

110mm

(4.5in)

diameter

air

duct

required.

(b)

Reduce

the

air

duct

'A'

to

L +

28mm

(1.1in).

Note.

that

one

end

of

the

duct

has

two

holes

drilled.

DO

NOT CUT FROM THIS END

OF

THE DUCT.

2.

Cut

the

flue

duct

to

length

as

follows:-

(a)

Take

wall

thickness

Land

add

51mm

(2.0in).

This

is

the

overall

length

of

60mm

diameter

(2.38in)

flue

duct

required.

(b)

Reduce

the

flue

duct

to

'C'

to

L +

51mm

(2.0in)

by

cutting

from

either

end.

(Fig 9).

3.

Refer

to

Figs 6 &

7.

Slacken

the

vertical

air

duct

clam-

ping

screw

sufficient

to

allow

the

air

duct

blanking

plate

to

be

pulled

out

of

its

socket.

This

will

facilitate

access

to

the

rear

flue

duct

clamping

screw.

Depending

on

wall

thickness

and

space

available

the

flue

duct

only

should

either:-

(a) Be

passed

through

the

wall

from

outside

and

then

fixed

into

the

socket

at

the

rear

of

the

flue

duct

housing

(Fig 8)

or

(b)

If

the

flue

duct

is

relatively

short

e.g.

less

than

400mm

{16in)

it

may

be

fixed

directly

to

the

flue

duct

housing

prior

to

moving

the

boiler

into

posi-

tion

in

front

of

the

inner

wall

face. (Fig 8).

4.

Remove

the

backing

paper

from

the

square

sealing

gasket

provided.

Position

the

gasket

as

shown,

then

press

the

adhesive

backed

side

firmly

against

the

back

panel,

around

the

rear

flue

outlet

(Fig 8).

Either

(a)

Apply

a

bead

of

silicone

sealant

around

the

inside

of

the

rear

flue

duct

socket

and

around

the

inside

of

the

rear

air

duct

socket.

Move

the

appliance

into

position,

square

to

the

wall

face,

standing

centrally

in

front

of

the

hole

in

the

wall.

Position

the

back

pane140mm

{1.6in) in

front

of

the

watl

face. Pass

the

flue

duct

through

the

wall

and

push

the

end

fully

home

into

the

rear

flue

duct

socket.

Working

through

the

top

air

duct

socket

tighten

the

rear

flue

duct

clamping

screw.

Make

sure

the

flue

duct

is

pos-

itioned

concentrically

within

the

rear

air

duct

socket

and

the

hole

in

the

wall.

or

(b) Push

one

end

of

the

flue

duct

fully

home

into

the

rear

flue

duct

socket.

Working

through

the

top

air

duct

socket

tighten

the

rear

flue

duct

clamping

screw.

Make

sure

the

flue

duct

is

positioned

con-

centrically

within

the

rear

air

duct

socket.

Move

the

appliance

into

position,

square

to

the

wall

face,

with

the

back

panel

about

40mm

(1.6in)

in

front

of

the

wall.

Allow

the

flue

duct

to

pass

into

the

hole

and

check

the

duct

is

positioned

concentrically.

5.

Fit

the

flue

terminal

into

the

end

of

the

air

duct

with

holes.

Slide

the

flue

terminal

into

the

air

duct

up

to

the

rolled

stop

channel.

Using

the

holes

in

the

air

duct

as a

guide

drill

through

the

flue

terminal

with

the

3mm

drill

supplied.

Screw

the

assembly

together

with

two

No

6 x

10mm

self-tapping

screws

provided.

(Fig 10).

6.

RECHECK

THAT

ANY

STUB

PIPE

CONNECTIONS

RE-

QUIRED HAVE

BEEN

MADE. (SECTION 9.3).

7.

Working

from

outside

pass

the

air

duct

and

terminal

assembly

through

the

hole.

A

flue

expansion

joint

of

about

100mm

{4in) is

allowed

for.

The

short

section

of

flue

duct

inside

the

terminal

will

engage

and

push

over

the

section

of

flue

duct

connected

to

the

boiler,

provided

the

air

and

flue

duct

have

been

cut

ac-

curately.

10

Fig. 8 Rear Flue

Application

FLUE DUCT HOUSING

PLAN VIEW

,,

"

CLAMPING

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

SCREW

P~b.R

FLUE

OUTLET

SOCKET

SEALANT

SEALING

GASKET

BLANKING PLATE

REMOVED FROM TOP AIR

DUCT INLET SOCKET

TOP AIR/FLUE DUCT

CLAMPING SCREWS

BLANKING PLATE "

FITIED

IN TOP FLUE

OUTLET SOCKET

ACCESS PANEL, WITH

M5

SLOTIED

HEAD FIXING

SCREW

FOR

TOP FLUE OUTLET CLAMPING SCREW

REAR

AIR DUCT /

CLAMPING SCREW

OUTER

WALL

FACE

POSITION

SEALING GASKET

AROUND

REAR

FLUE OUTLET AS SHOWN

Fig.Ba OUTER

WALL

SEALING

GASKET

/

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