Benchmark CS1 User guide

Installation and Servicing Instructions
CS1
Wall mounted condensing boiler for central heating
6 720 610 577-00.10
ZB 7-28 CS1 GC-Number: 41 108 02
6 720 610 601 GB (03.02) OSW

6 720 610 601 GB (03.02)
2
Contents
Contents
Safety recautions 3
Symbols 3
1 Details of the a liance 4
1.1 EC Declaration of Conformity 4
1.2 Standard package 4
1.3 Description of appliance 4
1.4 Accessories 5
1.5 Casing dimensions 5
1.6 Layo t of appliance 6
1.7 F nction (with optional extra motorised valve) 7
1.8 Electrical wiring diagram 8
1.9 Technical data 9
2 Installation regulations 10
3 Installation 11
3.1 Important remarks 11
3.2 Sealed systems 11
3.3 Siting the appliance 13
3.4 Wall mo nting frame assembly 14
3.5 Pre-piping the system 14
3.6 Fitting the appliance 15
3.7 Checking the connections 16
3.8 Fl e Systems 16
3.8.1 Siting the Fl e Terminal 17
3.8.2 Installation of the fl e 18
3.8.3 Fl e d ct preparation and assembly 20
4 Electrical connections 21
4.1 Connecting the appliance 21
4.2 Mains Voltage external controls connections 22
4.3 Wiring to yo r system 22
4.3.1 Pre-wired Remote S Plan 22
5 Commissioning 23
5.1 Commissioning 23
5.2 Switching the appliance on/off 24
5.3 Switching on the central heating 24
5.4 System controls 24
5.5 Appliances with optional pl g-in
diverter valve: Setting hot water temperat re 25
5.6 Frost protection 25
5.7 P mp anti-seize f nction 25
5.8 Fa lt Condition 25
6 Individual settings 26
6.1 Mechanical settings 26
6.1.1 Checking the size of the expansion vessel 26
6.1.2 Setting the central heating flow temperat re 26
6.1.3 Changing the heating p mp characteristic 26
6.2 Settings on the Bosch Heatronic 27
6.2.1 Operating the Bosch Heatronic 27
6.2.2 Selecting the p mp control mode for central
heating mode (Service F nction 2.2) 27
6.2.3 Setting the anti-cycle time
(Service F nction 2.4) 27
6.2.4 Setting the maxim CH flow temperat re
(Service F nction 2.5) 28
6.2.5 Setting the switching difference
(Service F nction 2.6) 28
6.2.6 Setting the heating o tp t
(Service F nction 5.0) 28
6.3 Setting the gas/air ratio 28
7 Converting the a liance to
different gas ty es 29
7.1 Setting the gas/air ratio 29
7.2 Testing comb stion air/fl e gas at set
heat o tp t 31
7.2.1 Testing the O
2
or CO
2
level in the
comb stion air 31
7.2.2 Testing CO and CO
2
31
8 Maintenance 32
8.1 Pre-Service Check List 33
8.2 Description of servicing operations 34
8.3 Replacement of Parts 37
8.3.1 PCB control board and transformer 37
8.3.2 Fan Assembly 38
8.3.3 P mp 38
8.3.4 3-way diverter valve 38
8.3.5 3-way diverter valve motor 39
8.3.6 Sensors 39
8.3.7 Gas Valve 39
8.3.8 Electrode assembly 39
8.3.9 Press re ga ge 40
8.3.10Expansion vessel 40
8.3.11Press re Relief Valve 40
8.3.12B rner 40
8.3.13Primary Heat Exchanger 40
9 A endix 41
9.1 Fa lt Codes 41
9.2 Short parts list 42
9.3 Heating/hot water o tp t settings (N.G) 42
9.4 Heating/hot water o tp t settings (L.P.G) 42
9.5 Operational Flow diagrams 43
9.5.1 Central heating f nction 43

6 720 610 601 GB (03.02)
Safety recautions
3
Safety recautions
If you smell gas
B Turn off g s service cock t the meter.
B Open windows nd doors.
B Do not oper te ny electric l switches.
B Extinguish ny n ked fl mes.
B Telephone your g s comp ny.
If you smell fumes from the a liance
B Switch off ppli nce (see p ge 24).
B Open windows nd doors.
Fitting and modifications
B Fitting of the ppli nce or ny controls to the ppli-
nce m y only be c rried out by competent engi-
neer in ccord nce with the G s S fety (Inst ll tion
nd Use) Regul tions 1998.
B Flue systems must not be modified in ny w ys other
th n s described in the fitting instructions.
B This ppli nce is for use on se led prim ry systems only.
Maintenance
B The user is recommended: to h ve the system
regul rly serviced in order to ensure th t it functions
reli bly nd s fely.
B Use only origin l sp re p rts!
Combustible materials
B Do not store or use ny combustible m teri ls
(p per, thinners, p ints etc.) in the vicinity of the
ppli nce.
Health and safety
B This ppli nce cont ins no sbestos products.
B There is no potenti l h z rd due to the ppli nce
being electric lly uns fe.
B There re no subst nces used in the construction
th t re potenti l h z rd in rel tion to the COSHH
Regul tions (Control of Subst nces H z rdous to
He lth Regul tions 1988).
Combustion air/Ambient atmos here
B The combustion ir/ mbient tmosphere should be
kept free of chemic lly ggressive subst nces (e.g.
h logen ted hydroc rbons which cont in chlorine or
fluorine compounds). This will prevent corrosion.
Instructions to the customer
B Expl in to the customer how the ppli nce works
nd how to oper te it.
B Advise the user th t he/she must not m ke ny modi-
fic tions to the ppli nce or c rry out ny rep irs on it.
B These instructions re to be left with the user or t
the G s meter.
B Import nt: These instructions pply in the UK only.
Symbols
Safety instructions in this doc ment
are identified by a warning-triangle sym-
bol and are printed on a grey back-
gro nd.
i
Notes containing important information
are identified by the symbol shown on the
left. They are bordered by horizontal lines
above and below the text.

6 720 610 601 GB (03.02)
4
Details of the a liance
1 Details of the a liance
1.1 EC Declaration of Conformity
This ppli nce is in ccord nce with the pplic ble
requirements of the G s Appli nce Directive, Boiler
Efficiency Directive, Electrom gnetic Comp tibility
Directive nd the Low Volt ge Directive.
1.2 Standard ackage
• G s condensing boiler for centr l he ting
• W ll mounting fr me
• Cl mp for securing flue duct kit
• Fixings (screws etc.)
• Set of document tion for ppli nce
• Pre-plumbing m nifold
• Condens te dr in pipe.
1.3 Descri tion of a liance
• W ll-mounted ppli nce, siting not dependent on
room size
• N tur l g s models re low-emission ppli nces
• Multifunction displ y
• Bosch He tronic control system
• Autom tic ignition
• Modul ting control
• Full s fety systems incorpor ting Bosch He tronic
with fl me ionis tion monitoring, solenoid v lves nd
temper ture sensors
• Concentric flue/ ir duct with testing point for
CO
2
/CO
• Regul ted speed f n
• Pre-mix burner
• Temper ture control for centr l he ting
• S fety temper ture limiter in 24 V electric l circuit
• Three-speed centr l he ting pump with utom tic
vent
• Relief v lve, pressure g uge, exp nsion vessel
• Flue g s temper ture limiter (105 °C)
• Condens te Tr p
• Connecting possibility for S-Pl n System.
PIN CE-0085 BL 0507
Category
UK II
2H 3P
A liance Ty e C
13
, C
33
Table 1

6 720 610 601 GB (03.02)
Details of the a liance
5
1.4 Accessories
• St nd rd horizont l flue kit t 100 mm outside
di meter for flues upto 4 m in length.
• Flue duct kits for horizont l (125 mm outside
di meter) for flue lengths upto 13 m nd vertic l flue
systems for flue lengths upto 15 m. Fitting instruc-
tions re sent with these kits.
• He ting progr mmers
• Timer
• Security kit
• Motorised v lve is v il ble s n option l extr . If
this option is used then the DT2, TR2 Optimising
Room Thermost t nd the Night Set B ck Module
will be required.
1.5 Casing dimensions
Fig. 1
13 M nifold ssembly
101 Outer c se
103 F ci cover
X St nd rd Concentric Horizont l Flue System: min. 310 mm
Altern tive Concentric Flue System: min. 250 mm
Y St nd rd Concentric Horizont l Flue System: 158 mm
Altern tive Concentric Flue System: 121 mm
Z St nd rd Concentric Horizont l Flue System: 105 mm
Altern tive Concentric Flue System: 130 mm
*
For servicing the ppli nce
min.
5
min.
5
850
440 395
200
360
861
906
200
30
6 720 610 601- 01.3O
101
103
35
X
13
Y
120
600
Z
**
*
*

6 720 610 601 GB (03.02)
6
Details of the a liance
1.6 Layout of a liance
Fig. 2
4 He tronic control
6 He t exch nger s fety temper ture limiter
7 Testing point for g s supply pressure
8.1 Pressure g uge
9 Flue g s temper ture limiter
15 Relief v lve
18 Pump
18.1 Pump speed selector switch
20 Exp nsion vessel
27 Autom tic ir vent
29 Air g s Mixer unit
32.1 Electrode ssembly
36 Temper ture sensor in CH flow
43 CH flow
63 Adjust ble g s flow restrictor
64 Adjusting screw for min. g s flow volume
102 Inspection window
120 Fixing points
221.1 Flue duct
221.2 Combustion ir int ke
226 F n ssembly
295 Appli nce type sticker
234 Testing point for combustion products
234.1 Testing point for combustion ir
271 Flue duct
349 Cover pl te for twin flue duct connection
358 Condens te tr p
415 Cover pl te for cle ning ccess
416 Condens te collector
417 Clip for fixing outer c se
418 D t pl te
423 Siphon
8.1
29
102
226
234.1
271
416
221.1
221.2
20
43
9
63
358
64
7
417
15
4
18
415
6
36
32.1
234
349
120
418
295
6 720 610 596-01.2O
18.1
423
27

6 720 610 601 GB (03.02)
Details of the a liance
7
1.7 Function (with o tional extra motorised valve)
Fig. 3
4 Bosch He tronic control
6 Temper ture limiter, he t exch nger
7 Testing point for g s supply pressure
8.1 Pressure g uge
9 Flue g s temper ture limiter
13 M nifold
15 S fety v lve
18 Centr l he ting pump
20 Exp nsion vessel
26 Ch rging v lve
27 Autom tic vent
29 Mixer unit
29.1 Bi-met llic thermost t for combustion ir compens tion
30 Burner
32 Fl me sensing electrode
33 Igniter electrode
35 He t exch nger with cooled combustion ch mber
36 Temper ture sensor in CH flow
43 CH flow
45 G s inlet
47 CH return
52 Solenoid v lve 1
52.1 Solenoid v lve 2
55 Filter
56 G s v lve CE 427
57 M in v lve disc
61 Reset button
63 Adjust ble g s flow restrictor
64 Adjusting screw for min. g s inlet flow volume
69 Control v lve
71 Stor ge w ter he ter outflow (only with motorised v lve)
72 Stor ge w ter he ter return (only with motorised v lve)
84 Motor (option l extr )
88 3-w y v lve (option l extr )
221 Flue duct
226 F n
229 Inner c sing
234 Testing point for flue g s
234.1 Testing point for combustion ir
317 Displ y
358 Condens te tr p
423 Siphon
443 Di phr gm

6 720 610 601 GB (03.02)
8
Details of the a liance
1.8 Electrical wiring diagram
Fig. 4
4.1 Ignition tr nsformer
6Temper ture limiter, he t exch nger
9Flue g s temper ture limiter
18 Pump
32 Fl me sensing electrode
33 Ignition electrode
36 Temper ture sensor in CH flow
52 Solenoid v lve 1
52.1 Solenoid v lve 2
56 G s v lve CE 427
61 Reset button
84 Motor (option l extr )
135 M ster switch
136 Temper ture control for CH flow
151 Fuse, slow 2.5 A, AC 230 V
153 Tr nsformer
161 Link
226 F n
300 Code plug
302 E rth connection
310 Temper ture control for hot w ter
312 Fuse, slow T 1,6 A
313 Fuse, slow T 0,5 A
314 Connector for progr mmer TA212E
315 Termin l block for progr mmer
317 Digit l displ y
318 Connector for timer
328 Termin l block for AC 230 V M ins supply
328.1 Link
363 Indic tor l mp for burner
364 Indic tor l mp for power supply
365 “Chimney sweep” button
366 Service button
367 ECO button
6
9
32
33
36
52.1
52
56
61
230 V
135
25 V
230V/AC
153 136
151 124789
315
161
M
226
300
LNLs
Ns
328
LR
302
310
312
313
314
317
318
363
364 365 366
ECO
367
4.1
328.1
M
18
6 720 610 601-02.2O
mains supply
r
r
bl
bl
bl
bl
o
o
o - orange bl - black r - red
84
M
p
p
p

6 720 610 601 GB (03.02)
Details of the a liance
9
1.9 Technical data
Units Natural gas Pro ane
M x. r ted he t output net 40/30˚C centr l he ting
M x. r ted he t output net 50/30˚C centr l he ting
M x. r ted he t output net 80/60˚C centr l he ting
kW
kW
kW
29.3
29.0
27.4
29.3
29.0
27.4
M x. r ted he t input net kW 27.7 27.7
Min. r ted he t output net 40/30˚C
Min. r ted he t output net 50/30˚C
Min. r ted he t output net 80/60˚C
kW
kW
kW
8.4
8.3
7.4
11.6
11.4
10.5
Min. r ted he t input net kW 7.6 10.8
Maximum gas flow rate – After 10 minutes from lighting
N tur l g s G20 (CVnet 34.02 MJ/m3)m
3/h 2.9 -
LPG (CVnet 88 MJ/m3) kg/h - 2.1
Gas su ly ressure
N tur l g s G20 (CVnet 34.02 MJ/m3) mb r 20 -
LPG (CVnet 88 MJ/m3) mb r - 37
Ex ansion vessel
Ch rge pressure b r 0.75 0.75
Tot l c p city l 10 10
Flue
Flue g s temp. 80/60˚C, r ted/min. lo d ˚C 67/55 67/55
Flue g s temp. 40/30˚C, r ted/min. lo d ˚C 43/32 43/32
Residu l delivery pressure
(inc. pressure drop in ir int ke duct) P 80 80
CO2 level t m x. r ted he t output
CO2 level t min. r ted he t output
%
%
9.2
8.8
10.8
10.5
NOx-cl ss 5 5
SEDBUK figure, B nd A % 90.7 90.7
Condensate
M x. condens tion r te (tR = 30˚C) l/h 2.3 2.3
pH-v lue, pprox. 4.8 4.8
General Data
Electric l power supply volt ge AC ... V 230 230
Frequency Hz 50 50
M x. power consumption W 101 101
Noise output level dB(A) 36 36
Appli nce protection r ting IP X4D X4D
M x. CH flow temper ture ˚C nom. 90 nom. 90
M x. permissible oper ting pressure (CH) b r 2.5 2.5
Permissible mbient temper tures ˚C 0 - 50 0 - 50
Nomin l c p city of ppli nce l 3.75 3.75
Weight (excluding p cking) kg 46 46
Table 2

6 720 610 601 GB (03.02)
10
Installation regulations
Condensate analysis, mg/l
Flue system
Elbow - 90 ° Equiv lent length 2 m
Bend - 45 ° Equiv lent length 1m
Gas su ly
2 Installation regulations
G s S fety (Inst ll tion & Use) Regul tions 1998: All
g s ppli nces must be inst lled by competent per-
son. F ilure to inst ll correctly could le d to prosecu-
tion.
The m nuf cturers notes must not be t ken, in ny w y,
s overriding st tutory oblig tions.
The ppli nce must be inst lled in ccord nce with the
current IEE Wiring Regul tions, loc l Building Regul -
tions, Building St nd rds (Scotl nd) (Consolid tion),
bye-l ws of the loc l W ter Comp ny, He lth nd
S fety Document 635 (Electricity t Work Regul tions
1989) nd ny other loc l requirements.
Product Li bility regul tions indic te th t, in cert in cir-
cumst nces, the inst ller c n be held responsible, not
only for mist kes on his p rt but lso for d m ge result-
ing from the use of f ulty m teri ls. We dvise the
inst ller to void ny risk by using only qu lity pproved
br nded fittings.
The relev nt British St nd rds should be followed i.e.
• BS 6798: Specific tion for the inst ll tion of g s
fired hot w ter boilers of r ted input not exceeding
60kW
• BS 5449: Centr l He ting for Domestic Premises
• BS 5546: Inst ll tion of g s hot w ter supplies for
domestic purposes
• BS 5440:1: Flues nd ventil tion for g s ppli nces
of r ted input not exceeding 70 kW (net): Flues
• BS 5440:2: Flues nd ventil tion for g s ppli nces
of r ted input not exceeding 70 kW (net): Air
Supply
• BS 6891: Inst ll tion of low pressure g s pipework
inst ll tions up to 28 mm (R1).
• BS 7074:1: Code of pr ctice for domestic he ting
nd hot w ter supply
• BS 7671: Requirements for Electric l Inst ll tion.
These instructions must be followed.
Ammonium 1.2 Nickel 0.15
Le d ≤ 0.01 Mercury ≤ 0.0001
C dmium ≤ 0.001 Sulph te 1
Chromium ≤ 0.005 Zinc ≤ 0.015
H logen ted
hydroc rbons ≤ 0.002
Tin ≤ 0.01
Hydroc rbons 0.015 V n dium ≤ 0.001
Copper 0.028 pH-v lue 4.8
Table 3
HORIZONTAL 100 mm – Standard
Over ll Di meter of Duct mm 100
M x.
4 m
Flue Termin l / Duct
Assembly Length
mm 600
Extension Duct Length mm 1000
Table 4
ALTERNATIVE HORIZONTAL 125 mm FLUE
SYSTEM
Over ll Di meter of Duct mm 125 M x.
13 m
(inclu-
ding
turret)
Flue Termin l / Duct Assembly mm 1030
Table 5
VERTICAL 125 mm FLUE SYSTEM
Over ll Di meter of Duct mm 125 M x.
15 m
Flue Termin l / Duct Assembly mm 1360
Table 6
Total length of gas su ly i e
(metres)
Pi e diameter
(mm)
369
G s disch rge r te (m3/h)
8.7 5.8 4.6 22
18.0 12.0 9.4 28
Table 7

6 720 610 601 GB (03.02)
Installation
11
3 Installation
3.1 Im ortant remarks
BAppli nce should only be inst lled in se led centr l
he ting systems.
BTo void g s form tion in the system, g lv nised
r di tors or pipes must not be used.
BIf room thermost t is used: do not fit thermost tic
r di tor v lve on the r di tor in the prim ry room.
BAdd suit ble nti-freeze fluid comp tible with lu-
minium to the w ter in the centr l he ting system.
Suit ble products re v il ble from Betz-De rborn
Tel.: [phone] nd Fernox Tel.: 01799
550811.
BIn our experience, the ddition of se ling gents to
the w ter in the centr l he ting system c n c use
problems (deposits in the he t exch nger). For th t
re son we dvise g inst their use.
3.2 Sealed systems
The ppli nce must not be oper ted without the system
being full of w ter, properly vented nd pressurised.
The exp nsion vessel h s volume of 10 litres nd is
ch rged to pressure of 0.75 b r.
The w ter c p city of the system is shown in t ble 10,
p ge 26. If gre ter c p city is required then n ddi-
tion l exp nsion vessel must be fitted into the system
return s close to the ppli nce s possible. The system
pressure c n be set up to m ximum of 1.5 b r with 1
b r being the norm l setting.
If the system pressure is gre ter th n 2.5 b r when the
ppli nce is oper ting t m ximum temper ture then n
ddition l exp nsion vessel must be fitted into the sys-
tem return s close to the ppli nce s possible.
The filling point must be t low level nd rr nged s
shown in figs. 5 nd 8.
The pressure relief v lve is set to oper te t 3 b r.
There must be no connection to the m ins without the
pprov l of the loc l w ter comp ny. All connections in
the system must be c p ble of withst nding pressure
of up to 3 b r nd the r di tor v lves conform to the
requirements of BS 2767:10.
If Thermost tic R di tor V lves re fitted then it is rec-
ommended th t prim ry r di tor is left open.
Repe ted venting prob bly indic tes le k nd this
must be rectified to ensure the proper oper tion of the
ppli nce.
No galvanised radiators or i es must be used.
If any system water treatment is required then
only roducts suitable for use with Aluminium
shall be used i.e Fernox- Co al or Su erconcen-
trate or Sentinal X100, in accordance with the
manufacturers instructions. The use of any other
substances will invalidate the guarantee. The H
value of the system water must be less than 8 or
the a liance guarantee will be invalidated.
A dr in cock to BS2879 must be fitted to the lowest
point of the system.
IMPORTANT: Check that no dirt is left in the
water i ework as this could damage the a li-
ance. Thoroughly flush the heating system and
the mains water su ly before fitting the a li-
ance to the wall in accordance with the recom-
mendations of BS7593:1992.
BAlways t rn off the gas cock before car-
rying o t any work on components
which carry gas.
iFixing of the appliance, gas and fl e con-
nections, commissioning of the system
and electrical connections may only be
carried o t by competent persons a thor-
ised by CORGI.

6 720 610 601 GB (03.02)
12
Installation
Fig. 5 System layout if using built-in diverter valve
Fig. 6 System layout if using external diverter valve
RV
LV LV
RV
RV
RV
LV LV
INDIRECT
CYLINDER
APPLIANCE
Refer to
Appliance
Water
Flow
Diagram
Heating Return
Heating Flow
Safety Discharge
Cylinder Return
Hot Water Flow
BS
Stop Valve Fixed Cylinder Type
Mains Cold Water
Radiator Valve - Flow RV
Lockshield Valve - Return LV
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
6 720 610 601-04.1O
6 720 610 601-05.1O
RV
LV LV
RV
RV
RV
LV LV
INDIRECT
CYLINDER
APPLIANCE
Refer to
Appliance
Water
Flow
Diagram
Heating Return
Heating Flow
Safety Discharge
Cylinder Return
Hot Water Flow
BS
Stop Valve Fixed Cylinder Type
Mains Cold Water
Radiator Valve - Flow RV
Lockshield Valve - Return LV
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
Diverter
Valve

6 720 610 601 GB (03.02)
Installation
13
Fig. 7 System layout if using t in zone valves (S) plan
Fig. 8
3.3 Siting the a liance
Regulations concerning the Installation Site
BRelev nt n tion l regul tions must be complied with
section 3.8.1.
BConsult the inst ll tion instructions for det ils of min-
imum cle r nces required.
Combustion air
In order to prevent corrosion, the combustion ir must
not cont in ny corrosive subst nces.
Subst nces cl ssed s corrosion-promoting include
h logen ted hydroc rbons which cont in chlorine nd
fluorine compounds nd re cont ined in some sol-
vents, p ints, dhesives, erosol propell nts nd
household cle ners, for ex mple.
Surface tem erature
The m x. surf ce temper ture of the c sing nd the flue
is less th n 85 °C.
This me ns th t, no speci l s fety prec utions re
required with reg rd to fl mm ble building m teri ls
nd fitted furniture. The specified cle rences must be
m int ined.
Cu board/Com artment
The ppli nce c n be inst lled in cupbo rd/comp rt-
ment need for iring clothes providing th t the require-
ments of BS 6798 nd BS 5440:2 re followed. The
low c sing losses from the ppli nce elimin te the need
for ventil tion openings in the comp rtment.
6 720 610 601-06.1O
RV
LV LV
RV
RV
RV
LV LV
INDIRECT
CYLINDER
APPLIANCE
Refer to
Appliance
Water
Flow
Diagram
Heating Return
Heating Flow
Safety Discharge
Cylinder Return
Hot Water Flow
BS
Stop Valve Fixed Cylinder Type
Mains Cold Water
Radiator Valve - Flow RV
Lockshield Valve - Return LV
Note:
A drain cock
should be fitted
at the lowest
point of the
heating circuit
and beneath
the appliance
CH
Zone
Valve
DHW Zone Valve
Heating return
Non return
valve Non return valve Hose union
Test cock Temporary hose
Stop cock
Auto
air vent
Heating return
Stop
cock
Fill point
Non return
valve
Make up
vessel
1000mm (39 in)
above the highest
point of the system.
Sealed system filling and make up
6 720 611 137 - 29.1O

6 720 610 601 GB (03.02)
14
Installation
3.4 Wall mounting frame assembly
BT ke the w ll mounting fr me out of the p ck ge nd
screw together with 6 screws s shown in fig. 9. Use
the inner lugs on the top nd bottom horizont l sec-
tions for the ppli nces th t re 440 mm wide.
Fig. 9
BHold the w ll-mounting fr me g inst the w ll ensur-
ing th t it is vertic l.
BM rk the position of the flue duct hole if re r flue is
to be used. Refer to fig. 1 nd 18.
BM rk the holes for the w ll mounting fr me onto the
w ll, drill nd plug the holes nd screw the w ll
mounting fr me to the w ll with the screws provided.
Fig. 10
BScrew the pre-plumbing m nifold with two screws to
the w ll mounting fr me.
Fig. 11
3.5 Pre- i ing the system
Fig. 12 Manifold
43 CH flow
47 CH return
112 G s cock
171 Option l cylinder flow (used only with motorised v lve)
172 Option l cylinder return (used only with motorised v lve)
BA dr in t p should be fitted t the lowest point of the
centr l he ting system.
BWRAS pproved filling loop must be fitted.
6 720 610 576-04.1O
6 720 610 576-05.1O
6 720 610 576-11.1O
200
260
6 720 610 576-06.1O
35
120-130
50
4743 172112
171

6 720 610 601 GB (03.02)
Installation
15
Condensate Termination and Route
The condens te connection on the British G s/Bosch
ppli nces is in 22 mm pl stic. The pipe should be
extended nd run w y from the ppli nce with con-
st nt f ll of 2.5 ° or 40 mm in every metre.
The condens te pipe c n termin te into ny of four
re s:
Fig. 13
Whilst ll of the bove methods re ccept ble it is
lw ys the best pr ctice to termin te the condense
pipe vi n intern l w ste system.This will elimin te the
need for ny extern l condens te pipe runs which c n
be susceptible to freezing in extreme we ther.
Fig. 14 Position of the condensate drain
External condensate i ework
All British G s/Bosch condensing boilers h ve within
syphonic condens te tr p. R ther th n the condens te
const ntly dripping into the disch rge pipe, the con-
dens te is collected into tr p which rele ses it in
100 ml qu ntities.
This will help prevent freezing occurring.
If there is no ltern tive nd the condens te pipe h s to
be extern lly run, the following should be considered:
• The pipe run should t ke the shortest pr ctic l route.
• The pipework should be insul ted with we ther
resist nt insul tion.
• The pipe should termin te s close s possible to the
ground or dr in, whilst still llowing the condens te
to s fely disperse. This would prevent wind blowing
up the pipe.
• The pipework should be inst lled with the minimum
of horizont l runs nd with downw rd slope of t
le st 2.5 °.
3.6 Fitting the a liance
BRemove p cking, t king c re to observe the instruc-
tions on the p cking.
BLie the boiler on its b ck.
Removing the outer case
BTurn the clips with screwdriver (1.).
BSlide the outer c se upw rds nd then forw rds to
remove (2.).
Boiler
Boiler
Sink
Ø 22 min.
Ø 22 min.
Ø 22 min.
Ø 22 min.
Siphon
Siphon
75 min. trap
Invert
No length
restriction
No length
restriction
No length
restriction
Internal soil
and vent stack
The gradient of the discharge pipe
should be 2.5°(40 mm/m) minimum
The gradient of the discharge pipe
should be 2.5°(40 mm/m) minimum
The gradient of the discharge pipe
should be 2.5°(40 mm/m) minimum
An internal waste system An external waste system
The rainwater system An external purpose made soakaway
The gradient of the discharge pipe should be
2.5°(40 mm/m) minimum
Use waterproof pipe work
insulation in very exposed
positions
External length of
pipe 2m min.
Open end of pipe
direct into gully,
below ground but
above water level.
Open end of pipe
direct into gully,
below ground but
above water level
Open end of pipe direct
into gully, below ground
but above water level
75 min. trap
450 min.
Siphon
75 min. trap
Boiler
6 720 610 596 -03.1O
Boiler
Sink
6 720 610 602 - 03.1O
Benchmark: For optim m performance
after installation, this boiler and its asso-
ciated central heating system m st be
fl shed in accordance with the g ide-
lines given in BS5793:1992 “Treatment
of water in domestic hot water central
heating systems”.
iThe o ter case is sec red against na -
thorised removal by two clips (electrical
safety).
Always sec re the o ter case with those
clips again after refitting.

6 720 610 601 GB (03.02)
16
Installation
BRemove the pl stic c ps from the boiler connec-
tions.
Fig. 15
Fixing the a liance
BFit the w shers onto the g s nd w ter connections.
BLift the boiler onto the w ll-mounting fr me. The lugs
p ss through the rect ngul r holes in the boiler b ck
p nel.
BT ke c re not to disturb the w shers on the connec-
tions.
Connecting the flue assembly
BFit flue duct connector onto ppli nce flue spigot.
BSecure with the two screws supplied.
Fig. 16
BFor rem ining inst ll tion of flue ssembly, refer to
the relev nt inst ll tion instructions.
3.7 Checking the connections
Water connections
BCheck th t the O-rings or se ls re in pl ce before
tightening the connection.
BTurn on the service v lves for centr l he ting flow
nd return nd fill the he ting system through
WRAS pproved filling loop.
BCheck ll se ls nd unions for le ks (testing pres-
sure m x. 3.0 b r s indic ted by pressure g uge).
BCheck ll connections for le ks.
Gas su ly i e
BCheck th t the se l is in pl ce before tightening the
connection.
BTurn off g s cock to protect g s v lve g inst d m-
ge from excessive pressure.
BCheck g s supply pipe.
BRele se the pressure on the g s supply pipe.
3.8 Flue Systems
The only flue systems th t m y be used re those sup-
plied with the boiler.
The flue system must be inst lled in ccord nce with
the requirements of BS 5440:1.
Standard 100 mm flue system
The st nd rd concentric flue system provides for hor-
izont l length of upto 4 m. Full instructions for fitting this
flue re in Subsection 3.8.2 “Inst ll tion of the flue”.
Alternative 125 mm diameter flue systems
Installation instructions for the alternative flue
systems are sent with the a ro riate flue kit.
Systems re v il ble to give m ximum horizont l
length of 13 m.
A vertic l flue system upto height of 15 metres is v il-
ble.
45° nd 90° flue bends c n be used with correspond-
ing reduction in flue length of 2 m for e ch 90° bend
nd 1 m for e ch 45° bend used.
IMPORTANT: Any horizont l flue system fitted to
condensing boiler must incline tow rds the ppli nce t
n ngle of 3 % (30 mm per metre length) to prevent
condens te dripping from the flue termin l. This
means that the clearance above the a liance
must be increased to match the duct length.
Refer to fig. 1 on age 5.
1.
2.
6 720 610 332-07.1R
6 720 610 332-09.2R
1
3
2
4
1 .
2 .

6 720 610 601 GB (03.02)
Installation
17
3.8.1 Siting the Flue Terminal
The flue must be inst lled in ccord nce with
BS 5440:1 nd the Building Regul tions. Flue termi-
n ls in c rports nd under b lconies re to be voided.
The termin l must be positioned so th t it does not
c use n obstruction nor the combustion products
nuis nce. See fig. 17 nd t ble 8.
The termin l will, t times, give out plume of w ter
v pour nd consider tion must be given to this when
choosing termin l position. Keep cle r of security
lighting, ctiv ted by p ssive infr -red sensing he ds.
If the termin l is less th n 2 m bove surf ce to which
people h ve ccess then gu rd must be fitted. The
gu rd must be evenly sp ced bout the termin l with
sp ce of 50 mm in e ch direction nd fixed with pl ted
screws.
A gu rd Type K6 for the st nd rd horizont l flue, c n be
obt ined from Tower Flue Components, V le Rise, Ton-
bridge TN9 1TB.
Fig. 17
Minimum dimensions of flue terminal ositions (all ty es) (see fig. 17)
Dimension Terminal Position (kW in ut ex ressed in net) Balanced flues room sealed: Fanned draught
A1) Directly below n opening, ir brick, opening windows, etc. 300 mm
B 1) Above n opening, ir brick, opening window, etc. 300 mm
C 1) Horizont lly to n opening, ir brick, opening window, etc. 300 mm
D Below gutters, soil pipes or dr in pipes 75 mm
E Below e ves 200 mm
F 2) Below b lconies or c r port roof (lowest point) 200 mm
G From vertic l dr in pipe or soil pipe 150 mm
H From n intern l or extern l corner 300 mm
I Above ground roof or b lcony level 300 mm
J From surf ce f cing the termin l 600 mm
K From termin l f cing the termin l 1200 mm
L From n opening in the c r port (e. g. door, window) into the dwelling 1200 mm
M Vertic lly from termin l on the s me w ll 1500mm
N Horizont lly from termin l on the s me w ll 300 mm
O From the w ll on which the termin l is mounted Not pplic ble
P From vertic l structure on the roof Not pplic ble
Q Above intersection with roof Not pplic ble
Table 8
1) In ddition, the termin l should not be ne rer th n 150 mm (f nned dr ught) to n opening in the building f bric formed for the purpose of ccommo-
d ting built-in element such s window fr me.
2) Not recommended.

6 720 610 601 GB (03.02)
18
Installation
3.8.2 Installation of the flue
The st nd rd 100 mm di meter horizont l flue system
is suit ble for lengths upto 4 m.
Flues upto 650 mm do not require n extension duct
ssembly.
Flues between 1600 mm nd 4000 mm require exten-
sion duct ssemblies.
NOTE: Flue lengths between 650 mm nd 730 mm
c nnot be ccomod ted. Refer to fig. 19, 20, 21.
St nd rd system comprise: Flue turret - Flue turret
cl mp - Termin l ssembly - W ll se ling - pl tes.
Extension kit comprises: Air duct - Flue duct - Duct
cl mp. Refer to fig. 22.
Instructions for fitting other flue systems re p cked
with the relev nt flue kit.
Check th t the position chosen for the ppli nce is s t-
isf ctory. Refer to fig. 18.
Fig. 18 Marking the position of the side flue opening
Fig. 19 Standard Flue
Appliance
120
Drilling point for
flue duct opening
3 %
(30 mm/metre)
Centre
line of
flue
opening
and
appliance
Centre line of
flue/air duct
Top of the
wall
mounting
frame
H
H
Standard Horizontal Flue 158 mm
Optional Horizontal Flue 121 mm 6 720 610 602-07.2O
Flue
Turret
No
Clamp
Maximum 650 mm
Terminal
Assembly
Outer
Wall
6 720 610 602 - 08.1O

6 720 610 601 GB (03.02)
Installation
19
Fig. 20 Flue ith one extension
Fig. 21 Flue ith extensions
Fig. 22 Flue components
Maximum 1600mm
Flue
Turret
No
Clamp
Terminal
Assembly
Outer
Wall
Extension
Duct
6 720 610 602 - 09.1O
Clamp
Flue
Turret
No
Clamp
Clamp
Extension
Duct
Clamp
Extension
Duct
Terminal
Assembly
Outer
Wall
6 720 610 602 - 10.1O
Extension Air Duct
Extension Flue Duct
Terminal Assembly
Duct Clamp
Wall Sealing Plates
6 720 610 602 - 11.1O
Flue
Turret

6 720 610 601 GB (03.02)
20
Installation
3.8.3 Flue duct re aration and assembly
Me sure the flue length L. Refer to fig. 23, 24.
Fig. 23 Flue length - rear
Fig. 24 Flue length - side
M rk off the lengths shown onto the ducts nd cut to
length. The cuts must be squ re nd free from burrs.
Termin l ssembly outer ( ir) duct - L- 70 mm, inner
(flue) duct - L- 50 mm.The me surement is m de from
the ridge t the termin l indic ting the outer f ce of the
w ll. Refer to fig. 25.
Extension ir duct - L- 70mm, flue duct - L- 50 mm.
The me surement is from the formed end.
Fig. 25 Flue terminal position
Assemble flue system completely. Push the ducts fully
together nd cl mp in the positions. The slope of the
termin l outlet must f ce downw rds.
The ssembly will be m de e sier if solvent free
gre se is lightly pplied i.e V seline, to the m le end of
the ducts.
NOTE: An inner wall sealing late is rovided
which should be fitted to the ducts before assem-
bly.
Push the ssembly through the w ll nd fix the turret to
the ppli nce with the cl mp. Refer to fig. 26.
Fig. 26 Flue turret
Ensure th t the turret is fully entered into the socket on
the boiler. From the outside fix the outer w ll pl te to the
termin l nd, fter ensuring the duct is properly i nclined
tow rds the boiler, fix the pl te to the w ll.
If the termin l is within 2 m of the ground where there is
ccess then n pproved termin l gu rd must be fitted.
The gu rd must give cle r nce of t le st 50 mm
round the termin l n be fixed with corrosion resist nt
screws.
NOTE: THE FLUE MUST BE INCLINED T O THE
BOILER
L
120
6 720 610 602 - 12.1O
NOTE: THE FLUE MUST BE INCLINED T O THE
BOILER
L
6 720 610 602 - 13.1O
Outer
Wall
Face Flue Terminal
Raised Ring
locating the
terminal relative
to the outside
wall face
6 720 610 576 - 20.1O
Air and
Flue Duct
Entry into
silicone
rubber seals
Flue Turret
Clamp
Flue Socket
on Boiler 6 720 610 602 - 14.1O