andrews CSC39 User manual

Working towards
a cleaner future
CSC
Installation Guide, Operation & Service Manual
This manual must be kept with the appliance August 2011
Part No E191
Natural Gas, Propane & Butane Fired
Storage Water Heaters
MODELS CSC39, CSC59, CSC78, CSC93, CSCL39, CSCL59, CSCL78, CSCL93
Auto Ignition
E191 CSC_NatGas+LPG overs 23/8/11 14:55 Page 1

© Copyright Andrews Water Heaters 2007
Reproduction of any information in this publication by any method is not permitted
unless prior written approval has been obtained from Andrews Water Heaters.
Andrews Storage Water Heaters have been designed and manufactured to comply
with current International standards of safety. In the interests of the health and
safety of personnel and the continued safe, reliable operation of the equipment,
safe working practices must be employed at all times. The attention of U.K. users is
drawn to their responsibilities under the Health and Safety Regulations 1993.
All installation and service on the Andrews Water Heater must be carried out by
properly qualified personnel, and therefore no liability can be accepted for any
damage or malfunction caused as a result of intervention by unauthorised
personnel.
The Andrews Water Heaters policy is one of continuous product improvement, and
therefore the information in this manual, whilst completely up to date at the time of
publication, may be subject to revision without prior notice.
Further information and assistance can be obtained from:
Andrews Water Heaters
Wood Lane, Erdington, Birmingham B24 9QP
Tel: [phone] Fax: [phone]
Sales: 0845 070 1056
Technical: 0845 070 1057
Service: 0845 070 1058
Email: [email protected]
www.andrewswaterheaters.co.uk
THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL
ARE FOR USE WITH NATURAL GAS OR LPG (PROPANE OR BUTANE) GAS ONLY

CONTENTS
SECTION 1 GENERAL AND SAFETY INFORMATION
General Information 2
British Standards and Codes of Practice 2
Health and Safety Regulations 1993 3
Effectiveness in Combating Legionellae 3
SECTION 2 TECHNICAL DATA 4
SECTION 3 INSTALLATION
Introduction 6
Location 6
Gas Supply - Natural Gas 7
Gas Supply - LPG (Propane or Butane) Gas 8
Electrical Supply 10
Flue Systems 11
Air Supply and Ventilation 17
Water Quality and Treatment 19
Water Connections 20
SECTION 4 COMMISSIONING
Filling the Heater with Water 24
Draining Water from the Heater 24
Lighting the Burner 24
Shutting Off the Burner 25
Checking Main Burner Pressure 25
Checking Pilot and Burner Flames 25
User's Safety Guide 26
SECTION 5 OPERATION
Operating Sequence 27
ECO (Energy Cut-Off) 27
Temperature Stratification (Stacking) 27
SECTION SERVICING
Introduction 28
Pre-Service Operations 28
Annually 28
Si Monthly 28
Burner Assembly 29
Gas Control Valve 29
Magnesium Anodes 29
Combined Temperature and Pressure Relief Valve 30
Cleaning the Storage Vessel 30
Restart 30
SECTION 7 FAULT FINDING 31
SECTION 8 PARTS LISTS AND ILLUSTRATIONS 32
PAGE

GENERAL AND SAFETY INFORMATIONSECTION 1
The Andrews Water Heater has been designed for use with NATURAL GAS OR LPG
(PROPANE OR BUTANE) GAS only and is manufactured to give an efficient, reliable and
long service life.
To ensure the continued, trouble-free operation of your heater at ma imum efficiency, it
is essential that correct installation, commissioning, operation and service procedures are
carried out strictly in accordance with the instructions given in this manual. By law,
installation and commissioning of the heater must be carried out by properly qualified
personnel.
The heater(s) must be installed in accordance with the following requirements;
The current GAS SAFETY (INSTALLATION AND USE) REGULATIONS
The current BUILDING REGULATIONS
The WATER SUPPLY (WATER FITTINGS) REGULATIONS 1999
Additionally, installation should be performed in accordance with all relevant
requirements of the Gas Supplier, Local Authority and recommendations of the British
Standards and Codes of Practice detailed below.
BS 6700: 1997 Specification for design, installation, testing and maintenance of
services supplying water for domestic use within buildings and their
curtilages. This standard supersedes the following British Standards
and Codes of Practice: CP99, CP310, CP324, 202, CP342 Part 2,
Centralised Hot Water Supply.
BS 5440:2000 Installation of flues and ventilation for gas appliances of rated output
not e ceeding 60kW.
BS 6644 Installation of gas fired hot water boilers of rated inputs between
60kW and 2MW.
BS 5546:1990 Installation of gas hot water supplies for domestic purposes.
BS 6891 Installation of low pressure gas pipework of up to 28mm in domestic
premises.
BS 7206:1990 Specification for unvented hot water storage units and packages.
I/M2 Purging procedures for industrial and commercial gas installations.
I/M11 Flues for commercial and industrial gas fired boilers and air heaters.
I/M16 Notes on installation of gas pipework (e cluding 25mm and below).
IGE/UP/10 Pt.1
Edition 2 Installation of Gas Appliances in Industrial and Commercial Premises
NOTE: Consideration should be given to amendments or updates to
the above standards.
GENERAL
INFORMATION
BRITISH
STANDARDS
AND CODES OF
PRACTICE
2

GENERAL AND SAFETY INFORMATION SECTION 1
It is the duty of manufacturers and suppliers of products for use at work to ensure, so far
as is practicable, that such products are safe and without risk to health when properly
used and to make available to users, adequate information about their safe and proper
operation.
Andrews Water Heaters should only be used in the manner and purpose for which they
were intended and in accordance with the instructions in this manual. Although the
heaters have been manufactured with paramount consideration to safety, the basic safety
precautions highlighted in this manual must be observed by the user.
It is imperative that all users of the heater must be provided with all the information and
instruction necessary to ensure correct and safe operation.
Water systems in buildings have been associated with outbreaks of Legionnaires' Disease,
particularly in health care facilities where occupants are significantly more susceptible to
infection.
In recognition of the risks in hospitals, a Code of Practice for the Control of Legionellae
in Health Care premises has been issued by the Department of Health (1991). Codes of
Practice applicable to other premises have been published by other organisations,
principally the Health and Safety E ecutive (HS)(G70) and the Chartered Institute of
Building Services Engineers (CIBSE, TM13).
All Codes of Practice draw attention to the design and operation of water systems with
reference to avoidance of factors that favour colonisation by Legionellae bacteria. These
factors include stagnation, lukewarm conditions (20ºC to 45ºC) and the accumulation of
debris, scale and corrosion in the base of tanks and calorifiers.
Andrews Water Heaters has commissioned an independent evaluation of their products
to investigate their resistance to build-up of legionellae bacteria.
E periments were conducted to determine whether, following a substantial challenge by
legionellae pneumophilia, after overnight and stagnation conditions, the system was
rendered free from viable recoverable legionellae. It was found that at 61ºC, following a
challenge of appro imately 107 organisms per litre, within one hour, more than 99.999%
of organisms had been killed. After a subsequent stagnation period, sampling did not
reveal any residual contamination. The design of the base of the water heater precludes
legionellae colonisation, even after build-up of debris. The burner positioning ensures
that the water at the bottom of the heater reaches the same, or higher temperature as in
the rest of the heater.
Based on data obtained through e periment, the Andrews Water Heater can be described
as legionellae resistant as it is considered unlikely that, at the temperature tested, the
organism would colonise the water heater and present a possible health risk.
HEALTH AND
SAFETY
REGULATIONS
1993
EFFECTIVENESS
IN COMBATING
LEGIONELLAE
3

ANDREWS MODEL NO
Storage Capacity l 276 276 276 350
gal 61 61 61 77
Recovery thro' 44ºC/80ºF l/h 749 1149 1517 1808
gal/h 165 253 334 398
Recovery thro' 56ºC/100ºF l/h 600 922 1213 1445
gal/h 132 203 267 318
Heat Input Gross kW 44 66 88 106
Btu/h 150,128 225,192 300,256 361,672
Heat Input Net kW 40 60 80 96
Btu/h 136,480 204,720 272,960 327,552
Gas Flow Rate m3/hr 4.09 6.15 8.20 9.88
ft3/hr 144.6 217.2 289.8 349.2
Gas Flow Rates LPG m3/hr 1.78 2.54 3.39 4.09
ft3/hr 63 90 120 144.6
Gas Family 12HNATURAL and I3LPG
Feed /Flow Connections Rp (BSP) 11⁄211⁄211⁄211⁄2
Return Connections Rp (BSP) 3⁄43⁄43⁄43⁄4
Gas Connection Rp (BSP) 3⁄43⁄43⁄43⁄4
Flue Gas Temperature ºC 137 160 171 171
Flue Gas Volume m3/hr 110 109 140 164
Ma . Working Pressure bar 10 10 10 10
lbf/in2150 150 150 150
Min. Working Pressure bar 0.15 0.15 0.15 0.15
lbf/in22.2 2.2 2.2 2.2
Burner Pressure mbar 11.25 11.25 11.25 11.25
Natural Gas ins wg. 4.5 4.5 4.5 4.5
Burner Pressure mbar 25 25 25 25
Propane & Butane ins wg. 10 10 10 10
Injector Diameter mm 2.4 2.9 2.9 3.1
in 0.094 0.114 0.114 0.122
Injector Diameter (LPG) mm 1.65 1.95 1.90 2.1
In 0.064 0.076 0.074 0.082
Weight Empty kg 340 340 345 381
Lb 750 750 760 840
Weight Full kg 636 636 641 727
Lb 1402 1402 1412 1603
Shipping Weight kg 354 354 358 399
Lb 780 780 790 880
Shipping Dimensions Height mm 2110 2110 2110 2110
In 83 83 83 83
Shipping Dimensions Width mm 770 770 770 770
In 30 30 30 30
Shipping Dimensions Depth mm 1210 1210 1210 1210
In 47 47 47 47
Mains Voltage V 220/240 - IP 20
Frequency Hz 50
Fuse A 5
TECHNICAL DATASECTION 2
DIMENSIONS
AND
CLEARANCES
4
CSC39 CSC59 CSC78 CSC93
CSCL39 CSCL59 CSCL78 CSCL93
(Natural Gas)

TECHNICAL DATA SECTION 2
5
A. Height of Heater mm 1623 1623 1623 1851
In 64 64 64 73
B. Diameter mm 720 720 720 720
In 28 28 28 28
C. Gas Connection mm 355 355 355 355
In 14 14 14 14
D. Cold Inlet mm 530 530 530 530
In 21 21 21 21
E. Optional Front Outlet mm 1307 1307 1535 1535
In 51 51 60 60
F. Height to Centre of Flue mm 2060 2060 1980 2217
In 81 81 78 87
G. Height to Flue Spigot mm 1780 1780 1780 2020
In 70 70 70 80
H. Min. Flue Horizontal mm 840 840 970 970
In 33 33 38 38
Ma . Flue Horizontal mm 7000 7000 7000 7000
In 276 276 276 276
. Min. Flue Vertical mm 1310 1310 1610 1610
In 51 51 63 63
Ma . Flue Vertical mm 7000 7000 7000 7000
In 276 276 276 276
J. Electrical Connection mm 1250 1250 1250 1480
In 49 49 49 58
K. Flue Diameter mm 100/150 100/150 130/200 130/200
L. Flue Adaptor mm 95 95
In 4 4
ANDREWS MODEL NO CSC39 CSC59 CSC78 CSC93 DIMENSIONS
AND
CLEARANCES
Not supplied with
these models
Horizontal or
Vertical Flue 1168mm
Minimum
Service
clearance
with
standard
Anodes.
500mm Recommended
or panel access and
switching. Absolute
min 300mm.
500mm Recommended or
panel access and switching.
Absolute min 300mm.
615mm
Minimum
Service
clearance
with Correx
Anodes.
Adaptor
Cold Water
Inlet 1⏲“
B.S.P.
Drain or Return
3/4” B.S.P.
Ideal Service clearance Dimensions
1125
Horizontal
Flue can
be rotated
360º
Tee & T/P Valve
supplied
Vent rom here
i used or Top
Hot Water outlet
‘X’
H
H
K
I
I
Can be
used or
Hot Water
outlet or
can be
capped
Alternative
Hot Water
outlet
I side connection is
used or Hot Water
outlet Air vent must
be itted at ‘X’
UNVENTED SYSTEM VENTED SYSTEM CSC78 and CSC93 Alternative Flue Systems
CSC39 and CSC59 Alternative Flue Systems
275.0
90.0
725.0 Min.
475.0
300mm
Minimum
N.B. Access o 500mm must be provided
one side or 6 months an lubrication

LOCATION
INSTALLATIONSECTION 3
THE LAW REQUIRES THAT INSTALLATION IS CARRIED OUT BY A
PROPERLY QUALIFIED PERSON
Installations must be carried out in accordance with Gas safety (Installation and Use)
Regulations 1998, Building Regulations, The Water Supply (Water Fittings) Regulations
1999 and any requirements of the local Gas Authority, Local Authority, Water and Fire
Authorities and the current British Standards and Codes of Practice listed in Section 1.
The location selected for installation of the heater must allow the provision of a
satisfactory flue, adequate air supply, drain facilities and must be well illuminated.
A purpose built boiler room or compartment is strongly recommended.
A manual valve for isolation of the boiler room should be installed in the gas supply; it
should be clearly identified and readily accessible for use at all times.
If a purpose built boiler room is not available, measures should be taken to protect the
heater from damage and prevent any e traneous matter from being stored on or around
the heater. See BS 6644 Clauses 4, 5 and 6 for details.
The heater must not be installed in any location which contains a bed, bath or shower.
There must be easy access to the boiler room and heater at all times.
The water heater must be located in an area where leakage from the tank, water
connections or the combination temperature and safety valve will not result in damage to
the area adjacent to the water heater. When such locations cannot be avoided, a suitable
drain tray must be installed under the water heater. The drain tray must be no deeper
than 38mm (1.5in) and have a minimum length and width of 100mm (4in) wider than
the heater. The drain tray must be piped to an adequate drain using 20mm (0.75in)
diameter pipe, angled for proper drainage.
Access must be provided to the front of the water heater and adequate clearance for it's
servicing and operation.
The floor on which the heater is installed must be flat, level and of sufficient strength to
withstand the weight of the heater when filled with water, and should satisfy the
requirements of the Local Authority & Building Regulations.
Any Combustible material adjacent to the heater must be so placed and shielded as to
ensure that it's temperature does not e ceed 66ºC (150ºF).
The minimum clearance to combustibles for the heater Is:
50mm (2in) from the front of the burner access bo .
Zero clearance from the air intake boot and vent tubes.
300mm (12in) from the direct vent terminal.
A minimum of 726mm (30 inches) from the burner access panel shall be provided for
inspection and servicing.
All service clearances to the water heater must be maintained as specified in the
CSC Range Installation and Design Guide.
INTRODUCTION
6

INSTALLATION SECTION 3
The installation of the gas supply must conform, depending on it's size, to the
requirements of British Standards and Codes of Practice listed in Section 1 of this manual.
A gas meter will be connected to the service pipe by British Gas plc or it's authorised
contractor.
The meter and service pipe should be checked by British Gas or it's authorised contractor
to ensure that they are adequate to deal with the gas supply to the water heater(s) in
addition to any e isting or additional requirements.
CAUTION!
DO NOT APPLY HEAT IN CLOSE PROXIMITY TO THE GAS CONTROL THERMOSTAT
AS THIS WILL RESULT IN DAMAGE OCCURRING TO THE CONTROL
Fit the gas cock immediately upstream of the gas control valve using a suitable jointing
compound and connect to the gas supply. An inlet nipple and m/f elbow is factory fitted
to the gas control valve to avoid possible damage.
Where the water heater(s) is(are) installed in a boiler house or purpose built
compartment, a manually operated valve for the boiler house must be fitted in
accordance with the Gas Safety (Installation and Use) Regulations 1998. The valve must
be easily identified and readily accessible.
After installation, the system should be pressure tested for soundness and purged in
accordance with BS 6891 or IM/2 and IM/5 as appropriate.
7
GAS SUPPLY
NATURAL GAS
Gas Cock
BSP Thread U.P.T. Thread
Nipple
Gas Valve
M/F Elbow
Fig 1.

INSTALLATIONSECTION 3
Contact Calor Gas who will provide the appropriate type and size of LPG supply vessel
and ensure it's safe location and installation.
The installation of the gas supply must conform to LPGA Code of Practice, 22 LPG Piping
Systems: Design and installation plus the requirements of British Standards and Codes of
Practice listed in Section of this manual.
PROPANE: 37mbar (14.86 in wg)
BUTANE: 28mbar (11.26 in wg)
When using propane or butane cylinders, connect a minimum number of cylinders as
listed below, together with a manifold before connecting to the union.
Use a minimum pipe size of 3⁄4in bore.
Two Cylinders CSCL39 and CSCL59
Three Cylinders CSCL78
Four Cylinders CSCL93
WARNING!
PROPANE AND BUTANE CYLINDERS MUST BE USED AND STORED IN
ACCORDANCE WITH 'THE HIGHLY FLAMMABLE LIQUIDS AND LIQUIFIED
PETROLEUM GASES REGULATIONS 1972', AND SHOULD COMPLY WITH LPGA
CODE OF PRACTICE 7, 'STORAGE OF FULL AND EMPTY LPG CYLINDERS AND
CARTRIDGES
GAS SUPPLY
PROPANE OR
BUTANE
8

INSTALLATION SECTION 3
9
BULK STORAGE
VESSEL
INSTALLATION
CYLINDER
INSTALLATION
Fig 2.
Regulator Set to
give 37 mbar
(14.86” Wg)
Propane
Pigtail
Assembly
Automatic
change over
device
Nipple
Regulator normally
fitted at tank
To bulk Supply
Installation of
Propane supply
1” Heavy Steel Sleeved
Pipe Through Wall
1” Heavy Steel Sleeved
Pipe Through Wall
Gas emergency
control at entry
point to building
Gas emergency
control at entry
point to building
Steel Liner sealed to
pipe at inside end
Steel Liner sealed to
pipe at inside end
Cylinder regulator Set to give
37 mbar (14.86”) Propane
3/4” Spring loaded gas cock
3/4” Spring loaded gas cock
Propane cylinder must be
outside building

INSTALLATIONSECTION 3
E ternal wiring to the water heater(s) must be installed in accordance with current I.E.E.
Regulations for the wiring of buildings and to any Local Regulations that may apply.
The Auto Ignition Heater is designed to operate from a 220/240V, 1Phase supply.
The fuse rating is 5 amps.
The method of connection to the mains electricity supply should facilitate complete
Electrical isolation of the appliance, preferably by use of a fused double pole switch or
fused spur bo serving only the heater. The disconnection of the supply shall have a
contact separation of 3mm in all poles.
The point of connection to the mains electricity supply should be readily accessible and
adjacent to the appliance.
Connect the electrical supply the main control panel terminal block via the cable glands in
the base of the control panel. Mains input cable should be 0.75mm2, 3 core, and should
be connected to the mains supply as detailed above.
It is recommended that screen cable is used where the volt-free contacts are to be
connected from an e ternal supply. This will eliminate the risk of possible interference
from nearby high voltage cables.
Mains Voltage: 220/240Volts - IP 20
Frequency: 50Hz
Fuse: 5 Amps
Fan Motor: 1.4 Amps
ELECTRICAL
SUPPLY
10
Fig 3.
Wiring diagram for
natural gas appliance
and LPG appliance.

INSTALLATION SECTION 3
11
Your Andrews Water Heater is a Direct Fan Flued Gas Water Heater where all air for
combustion is obtained from the outside atmosphere and all flue gases are charged to the
outside atmosphere. The flue system is a single coa ial (pipe within pipe) design where
the flue products are discharged through the inside flue tube and the combustion air
supply surrounds the flue surrounded by the outside pipe. The flue system incorporates
both combustion air supply and the flue e haust. The flue system component which is
outside the building and takes in the combustion air supply and discharges the flue
products (whilst keeping them separate) is referred to as the 'direct flue terminal'.
WARN NG!
The direct flue system must be properly installed. Failure to do so could result in property
damage or personal injury. DO NOT install any damaged components. Contact Andrews
Water Heaters for replacement parts. The flow of combustion air must not be restricted.
Keep direct flue terminal openings clear of any objects likely to cause flow restriction.
Direct Flue Terminal
Shall terminate at least 1.5m (5ft) above any forced air inlet located on the same wall.
This provision does not apply to the combustion air intake of a direct flue appliance or
the circulating air inlet and flue gas discharge of listed outdoor appliances.
Shall be installed with at least a 300mm (12in) flue termination clearance from any air
opening into a building.
The bottom of the direct flue terminal shall be located at least 300mm (12in) above
ground.
Consideration should be given to the location of the flue terminal. The flue terminal
should be located where the discharge of flue products does not cause a nuisance.
Consideration should also be given with regard to noise that may be emitted by this flue
system. In all cases the flue termination must meet the requirements of BS6644.
A suitable terminal guard must be fitted if less than 2 mtrs above ground level.
The Andrews Direct Fan Flued Gas Water Heater is supplied with one direct flue kit.
The flue system supplied with this water heater is a coa ial design with the flue discharge
tube on the inside and combustion air supply on the outside. Optional direct flue
components are available that can e tend the horizontal length and/or vertical height of
the direct flue to the ma imum distances listed in the table below. This water heater
must be installed using the supplied or optional listed components without modification.
Refer to the table on Page 36 for the various vertical and horizontal direct flue system
components.
NOTE! The supplied horizontal flue terminal may be used through outside walls up to
600mm (24in) thick.
Maximum Flue Distances (Horizontal or Vertical)
Number of 90º Elbows Ma imum length of straight pipe
(e cluding vent terminal) to e terior wall
0 7m (22ft 9in)
1 6m (19ft 6in)
2 5m (16ft 3in)
3 4m (13ft 0in)
NOTE! Each 45º elbow reduces the ma imum flue distance by 500mm (19.5in).
MPORTANT! Do not exceed the flue distances or the number of elbows listed
above. This may cause heater malfunction or an unsafe condition.
HORIZONTAL
AND VERTICAL
DIRECT FLUE
LENGTHS
FLUE
SYSTEMS

HORIZONTAL
AND VERTICAL
DIRECT FLUE
LENGTHS
INSTALLATIONSECTION 3
12
Installation Procedure
Determine location of flue exit.
1. The supplied kit includes a horizontal (through the wall) flue terminal, an elbow,
flue connector clamps and 2m (6.5ft) of coa ial flue pipe. The 150mm (6in) diameter
flue system is also supplied with a 200mm (8in) to 150mm (6in) reducer for the
waterheater flue connection. The coa ial flue pipe includes both the flue e haust
(inside pipe) and combustion air (outside pipe). The coa ial flue pipe may be cut on
the unflared end (end without gasket) as required for the installation.
2. Determine if additional flue components are required for the installation. Refer to the
flue component table below for available optional flue components.
3. Ensure that the flue terminal location complies with requirements described earlier and
the Local Gas Authority.
4. Measure the vertical and horizontal distance from the water heater flue connection to
determine the number of vent flue needed.
Flue Component Table for 150mm (concentric) ( in) Diameter Flue Size
(58.7 kWh 199,999 Btu/h Input Models).
SUPPLIED KIT COMPONENTS
Quantity Flue Length Part Description Part Number
1 90º Elbow E205
1 600mm (24in) Horizontal Flue Terminal E236
1 Large Stepped Adaptor Connection Clamp E237
1 200mm (8in) to 150mm (6in) flue reducer E238

INSTALLATION SECTION 3
13
Optional Components for 150mm (concentric) (6in) Diameter Flue Size
Quantity Flue Length Part Description Part Number
1 1 mtr Flue Pipe with clamp E202
1 1 mtr Cutable Flue Pipe with clamp E203
1 0.5 mtr Flue Pipe with clamp E204
1 90º Elbow E205
1 45º Elbow E206
1 1360mm (54in) Vertical Flue Terminal E239
1 Flat roof flashing for vertical
flue terminal with adjustable cap E207
1 Roof flashing for pitched roofs
150mm (6in) dia vent size E208
1 Wall Clamp 150mm (6in) dia. E209
Flue Component Table for 200mm (concentric) (8in) Diameter Flue Size
(88 kWh/300,00 Btu/h and 105.6kW/360,000 Btu/h nput Models.
SUPPLIED KIT COMPONENTS
Quantity Flue Length Part Description Part Number
1 90º Elbow E215
1 600mm (24in) Horizontal Flue Terminal E240
1 Large Stepped Adopter
Connection Clamp E237
Optional Components for 200mm (concentric) (8in) Diameter Flue Size
Quantity Flue Length Part Description Part Number
1 1 mtr Flue Pipe with clamp E212
1 1 mtr Cutable Flue Pipe with clamp E213
1 0.5 mtr Flue Pipe with clamp E214
1 90º Elbow E215
1 45º Elbow E216
1 Flat roof flashing for vertical
flue terminal with adjustable cap E217
1 Roof flashing for pitched roofs
150mm (6in) dia flue size E218
1 Wall Clamp 200mm (8in) dia. E219
FLUE
SYSTEMS

NSTALL NG THE FLUE TERM NAL
NOTE! The horizontal flue terminal supplied may be used through outside walls up to
600mm (24in) thick.
1 Horizontal flue Terminal (Through the Wall) supplied
a) Cut an opening of at least 165mm (6.5in) diameter through the outside for the
58.7kWh input models or 216mm (8.5in) for the 88kWh and 105.6kWh input models.
b) Slide the flue terminal through the wall opening to the rib closest to the intake air
openings of the terminal even with the outside wall.
c) Slide the outside wall plate over the flue terminal and fasten to the wall with four
screws. Depending on the wall construction, wall anchors may be required to reinforce
the screws.
d) Install inside wall plate on the inside wall and secure with four screws. Depending on
wall construction, wall anchors may be required to reinforce the screws.
FLUE
SYSTEMS
INSTALLATIONSECTION 3
14
Wall Anchor
(4 Places)
Wall Anchor
(4 Places)
Screw
(Supplied)
(4 Places)
Screw
(Supplied)
(4 Places)
flue Terminal
Flue Terminal
Outer Wall
Mount Plate
Inner Wall
Mount Plate
Intake Air Openings
(Must Face Ground)
Hole through Wall
Hole through Wall
Fig 4.
Fig 5.

INSTALLATION SECTION 3
15
FLUE
SYSTEMS
2 Vertical Flue Terminal (Through the Roof - Optional)
a) Determine the e act location where the roof flue terminal will e it the roof, ensuring
the flue system clears all obstructions. For pitched roofs, the flue cap must be the
distance above the roof line as specified, (300mm to base of Flue Clamp, minimum).
The top of the roof terminal may e tend up to 760mm (2.5ft) above the roof line as
required.
b) Run the coa ial flue system to the proper distance below the roof sheathing required
for the correct distance of the roof terminal above the roof surface. See the following
sections on installing the rest of the flue system.
c) Cut a minimum 165mm (6.5in) diameter hole for the smaller flue size or a 216mm
(8.5in) minimum diameter hole for the larger flue size centred in the desired location
for the roof terminal. See Fig. 6.
d) Centre the roof flashing over the hole using either the flat roof flashing or universal
flashing for pitched roofs.
e) Slip the storm collar supplied with the roof flashing kit over the outside of the flue
terminal and align with the flue pipe end below roof opening. Insert the terminal into
the flue pipe.
f) Fasten the roof flashing with nails. Seal the flue terminal and flashing to the roof.
g) Install the gasketed clamp around the joint between the flue terminal and flue pipe.
INSTALLING FLUE PIPING SECTIONS
a) The coa ial flue pipe sections are designed to fit tightly together and seal with the
integral flue pipe seal and supplied pipe clamps. No silicone caulk or special tools are
required.
b) All flue sections and fittings come complete with silicone flue pipe gaskets and outside
gasketed pipe clamps for making air tight connections between the flue pipe
connections.
d) Raise the flue pipe to the flue terminal connection with the gasketed end of the flue
pipe towards the flue terminal. Insert the flue pipe into the flue terminal connection
and grasp the end of the flue pipe while twisting and pushing the pipe until inserted
all the way into the flue terminal.
e) Connect the outside pipes together using the gasketed clamps provided. The flue
pipes have ribs located near each end. When the flue piping is connected, the
gasketed clamps shall cover the ribs and joints of the connecting flue tubes. Support
each pipe section with hangers attached to the supporting joists in the wall or ceiling.
f) Continue connecting pipe sections together with clamps and supporting with hangers.
Flat Roof
Flue Terminal
Storm Collar
Roof Flashing
(Nail & Seal
To Roof)
Hole Through Roof
Flue Terminal Pipe
Flue Terminal Pipe
Flue Pipe
(From Water Heater) Fig .

FLUE
SYSTEMS
INSTALLATIONSECTION 3
16
Fig 7.
Fig. 8.
g) The last pipe section may be cut to fit the distance required to reach the water heater
flue connections. First, install the condensate trap (supplied separately) with crimped
end into the gasketed end of the elbow (horizontal flue installations) and clamp the
condensate tee and elbow together. Then install the crimped end of the elbow into the
flue connection of the water heater. On vertical installations, install the the crimped end
of the condensate trap directly onto the water heater flue connection. The 58.7kWh
models require the installation of a flue reducer (supplied) into the water heater flue
assembly before attaching the elbow or condensate trap (vertical flue).
IMPORTANT! In order for the condensate trap to collect and dispose of the
condensate from the flue pipe, the flue system must have a downward slope
of 21mm per metre (0.25in/ft) towards the condensate trap. The condensate trap
must be installed as close as possible to the flue adaptor to prevent condensate
from accumulating and draining into the flue adaptor or blower.
h) Carefully measure the length of straight flue pipe needed, allowing for about 50mm
(2in) insertion into the elbow. Mark the ungasketed end of the pipe to be cut and
carefully make a straight cut on the outside pipe to the desired length. Make sure the
inside tube is not cut. Then cut the inside flue pipe about 50mm (2in) more than the
outside pipe so that the flue pipe protrudes slightly beyond the outside pipe. Connect
the flue pipe and clamp at each end.
i) Use the large clamp supplied in the flue kit with the stepped gasket to seal the elbow
or condensate trap to the blower flue connector. The larger step of the gasket seals
the flue pipe to the cast flue adaptor.
j) Condensate disposal: Connect either a 32mm (1.25in) slip joint drain connection or a
25mm (1in) PVC compression coupling from the condensate trap nipple to 25mm
(1in) PVC piping to a drain or condensate disposal pump. Install a drain trap after the
condensate fitting to seal the flue system.
Note: Condense tee & syphon MUST be fitted in ALL instances regardless of flue
length, this applies to both vertical & horizontal terminations.
Gasket End
Ribs Locked Beneath
Gasketed Clamp
Straight End
(Ungasketed)
Condensate Trap Nipple
Drain Trap
1”(25mm) Compression
Coupling or 11⁄4” (32mm)
Slip joint Connection
1”(25mm) PVC Piping
To Suitable Drain or
Condensate Disposable Pump

INSTALLATION SECTION 3
17
The following notes are intended to give guidance:
Where the heater is to be installed in a room, NO VENTS ARE REQUIRED.
Where the heater is to be installed in a compartment, permanent air vents are required in
the compartment at high and low level. These air vents must either communicate with a
room or internal space or be direct to outside air.
The minimum effective areas of the permanent air vents required in the compartment are
as follows:
Air Vents Areas
Position of Air Vents Air from Room or Internal Space Air Direct from Outside
High Level 10cm2per kW net 5cm2per kW net
Low Level 10cm2per kW net 5cm2per kW net
In a Room or No Requirement for Ventilation
Internal Space
Note: - Both air vents must communicate with the same room or internal space or
must both be on the same wall to outside air
Air vents should have negligible resistance and must not be sited in any position where
they are likely to be easily blocked or flooded or in any position adjacent to an e traction
system which is carrying flammable vapour.
Consideration must be given to the position of the high level ventilation opening. A high
level vent must not be sited within 300mm (1ft) measured vertically, of the flue terminal.
Grilles and louvres should be so designed that high velocity air streams do not occur
within the space housing the heater(s).
AIR SUPPLY
AND
VENTILATION

MPORTANT:
1. The effective area requirements specified in the table are related to the ma imum heat
input of of the heater(s), and are equivalent to those specified in BS6644 and
IGE/UP/10 Pt.1
2. The free area of the grilles should not be less than the size of the recommended
ventilation opening.
3. The supply of air to a space housing the heater(s) by mechanical means should be:-
(a) Mechanical inlet with natural e traction.
(b) Mechanical inlet with mechanical e traction.
NB!! Natural inlet with mechanical extraction must not be used
Where a mechanical inlet and mechanical e traction system is used, the design
e traction rate must not e ceed one third of the design inlet rate.
All mechanical ventilation systems must be fitted with automatic gas shut off safety
systems which cut off the supply of gas to the heater(s) in the event of failure of either
the inlet or e tract fans.
The requirements for air supply by mechanical ventilation are given in BS6644
Clause 19.3 and IGE/UP/10 Pt.1.
The permanent air vents shall be sited away from the e tract fans. It may be necessary
to increase the ventilation area to compensate for the e tractor fan.
INSTALLATIONSECTION 3
AIR SUPPLY
AND
VENTILATION
18