Bosch WORCESTER GREENSTAR HE ZB 7-27 User manual

Installation and Servicing Instructions
GREENSTAR HE system
Wall mounted condensing boiler for central heating
6 720 610 577-00.10
ZB 7-27 HE system GC-Number: 41 311 49
6 720 610 596 GB (01.07) OSW

6 720 610 596 GB (01.07)
2
Contents
Contents
Safety precautions 3
Symbols 3
1 Details of the appliance 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 Layout of appliance 6
1.7 Function 7
1.8 Electrical wiring diagram 8
1.9 Technical data 9
2 Installation regulations 11
3 Installation 11
3.1 Important remarks 11
3.2 Sealed systems 11
3.3 Siting the appliance 12
3.4 Wall mounting frame assembly 13
3.5 Pre-piping the system 13
3.6 Fitting the appliance 14
3.7 Checking the connections 15
3.8 Flue Systems 15
3.8.1 Siting the Flue Terminal 16
3.8.2 Installation of the flue 17
3.8.3 Flue duct preparation and assembly 19
4 Electrical connections 20
4.1 Connecting the appliance 20
4.2 Mains Voltage external controls connections 21
4.3 Wiring to your system 22
4.3.1 Pre-wired Remote Y Plan or 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 Frost protection 24
5.6 Pump anti-seize function 25
5.7 Fault 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 temperature 26
6.1.3 Changing the heating pump characteristic 26
6.2 Settings on the Bosch Heatronic 27
6.2.1 Operating the Bosch Heatronic 27
6.2.2 Selecting the pump control mode for
central heating mode (Service Function 2.2) 27
6.2.3 Setting the anti-cycle time
(Service Function 2.4) 27
6.2.4 Setting the maxim CH flow temperature
(Service Function 2.5) 28
6.2.5 Setting the switching difference
(Service Function 2.6) 28
6.2.6 Setting the heating output
(Service Function 5.0) 28
6.3 Setting the gas/air ratio 28
7 Converting the appliance to
different gas types 29
7.1 Setting the gas/air ratio 29
7.2 Testing combustion air/flue gas
at set heat output 31
7.2.1 Testing the O
2
or CO
2
level in
the combustion 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 36
8.3.1 PCB control board and transformer 36
8.3.2 Fan Assembly 37
8.3.3 Pump 38
8.3.4 Sensors 38
8.3.5 Gas Valve 38
8.3.6 Electrode assembly 39
8.3.7 Pressure gauge 39
8.3.8 Expansion vessel 39
8.3.9 Pressure Relief Valve 39
8.3.10Burner 39
8.3.11Primary Heat Exchanger 39
9 Appendix 40
9.1 Fault Codes 40
9.2 Short parts list 41
9.3 Heating/hot water output settings (N.G.) 42
9.4 Heating/hot water output settings (L.P.G) 42
9.5 Operational Flow diagrams 43
9.5.1 Central heating function 43

6 720 610 596 GB (01.07)
Safety precautions
3
Safety precautions
If you smell gas
y Turn off gas service cock at the meter.
y Open windows and doors.
y Do not operate any electrical switches.
y Extinguish any naked flames.
y Telephone your gas company.
If you smell fumes from the appliance
y Switch off appliance (see page 24).
y Open windows and doors.
Fitting and modifications
y Fitting of the appliance or any controls to the appli-
ance may only be carried out by a competent engi-
neer in accordance wth the Gas Safety (Installation
and Use) Regulations 1998.
y Flue systems must not be modified in any ways other
than as described in the fitting instructions.
y This appliance is for use on sealed primary systems
only.
Maintenance
y The user is recommended: to have the system
regularly serviced in order to ensure that it functions
reliably and safely.
y Use only original spare parts!
Combustible materials
y Do not store or use any combustible materials
(paper, thinners, paints etc.) in the vicinity of the
appliance.
Health and safety
y This appliance contains no asbestos products.
y There is no potential hazard due to the appliance
being electrically unsafe.
y There are no substances used in the construction
that are a potential hazard in relation to the COSHH
Regulations (Control of Substances Hazardous to
Health Regulations 1988).
Combustion air/Ambient atmosphere
y The combustion air/ambient atmosphere should be
kept free of chemically aggressive substances (e.g.
halogenated hydrocarbons which contain chlorine or
fluorine compounds). This will prevent corrosion.
Instructions to the customer
y Explain to the customer how the appliance works and
how to operate it.
y Advise the user that he/she must not make any modi-
fications to the appliance or carry out any repairs on it
y These instructions are to be left with the user or at
the Gas meter.
y Important: These instructions apply in the UK only.
Symbols
Safety instructions in this document
are identified by a warning-triangle sym-
bol and are printed on a grey back-
ground.
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.

6 720 610 596 GB (01.07)
4
Details of the appliance
1 Details of the appliance
1.1 EC Declaration of Conformity
This appliance is in accordance with the applicable
requirements of the Gas Appliance Directive, Boiler Effi-
ciency Directive, Electromagnetic Compatibility Direc-
tive and the Low Voltage Directive.
1.2 Standard package
• Gas condensing combination boiler for central
heating
• Wall mounting frame
• Clamp for securing flue duct kit
• Fixings (screws etc.)
• Set of documentation for appliance
• Pre-plumbing manifold
• Condensate drain pipe.
1.3 Description of appliance
• Wall-mounted appliance, siting not dependent on
room size
• Natural gas models are low-emission appliances
• Multifunction display
• Bosch Heatronic control system
• Automatic ignition
• Modulating control
• Full safety systems incorporating Bosch Heatronic
with flame ionisation monitoring, solenoid valves and
temperature sensors
• Concentric flue/air duct with testing point for
CO
2
/CO
• Regulated speed fan
• Pre-mix burner
• Temperature control for central heating
• Safety temperature limiter in 24 V electrical circuit
• Three-speed central heating pump with automatic
vent
• Relief valve, pressure gauge, expansion vessel
• Flue gas temperature limiter (105 °C)
• Condensate Trap
• Connecting possibility for Y-Plan or S-Plan System.
PIN CE-0085 BL 0507
Category
UK II
2H 3P
Appliance Type C
13
, C
33
Table 1

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6
Details of the appliance
1.6 Layout of appliance
Fig. 2
4 Heatronic control
6 Heat exchanger safety temperature limiter
7 Testing point for gas supply pressure
8.1 Pressure gauge
9 Flue gas temperature limiter
15 Relief valve
18 Pump
18.1 Pump speed selector switch
20 Expansion vessel
27 Automatic air vent
29 Air gas Mixer unit
32.1 Electrode assembly
36 Temperature sensor in CH flow
43 CH flow
63 Adjustable gas flow restrictor
64 Adjusting screw for min. gas flow volume
102 Inspection window
120 Fixing points
221.1 Flue duct
221.2 Combustion air intake
226 Fan assembly
295 Appliance type sticker
234 Testing point for combustion products
234.1 Testing point for combustion air
271 Flue duct
349 Cover plate for twin flue duct connection
358 Condensate trap
415 Cover plate for cleaning access
416 Condensate collector
417 Clip for fixing outer case
418 Data plate
419 Hose from automatic vent
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
27
415
6
36
32.1
234
349
120
418
295
419
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18.1
423

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Details of the appliance
7
1.7 Function
Fig. 3
4Bosch Heatronic control
6Temperature limiter, heat exchanger
7Testing point for gas supply pressure
8.1 Pressure gauge
9Flue gas temperature limiter
13 Manifold
15 Safety valve
18 Central heating pump
20 Expansion vessel
26 Charging valve
27 Automatic vent
29 Mixer unit
29.1 Bi-metallic thermostat for combustion air compensation
30 Burner
32 Flame sensing electrode
33 Igniter electrode
35 Heat exchanger with cooled combustion chamber
36 Temperature sensor in CH flow
43 CH flow
44 Hot water flow
45 Gas inlet
46 Cold water inlet
47 CH return
52 Solenoid valve 1
52.1 Solenoid valve 2
55 Filter
56 Gas valve CE 427
57 Main valve disc
61 Reset button
63 Adjustable gas flow restrictor
64 Adjusting screw for min. gas inlet flow volume
69 Control valve
221 Flue duct
226 Fan
229 Inner casing
234 Testing point for flue gas
234.1 Testing point for combustion air
317 Display
358 Condensate trap
419 Hose from automatic vent
423 Siphon
ϑ
33
29 30
32
226
229 234
234.1
9
35
221
26
6
36
29.1
63
15
45 47
20
43
13
8.1
69
64
57
52.1
56
52
55 7
317
61
4
max
max
1
2
345
E
ECO
0
358
27
18
419
423
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Details of the appliance
1.8 Electrical wiring diagram
Fig. 4
4.1 Ignition transformer
6Temperature limiter, heat exchanger
9Flue gas temperature limiter
18 Pump
32 Flame sensing electrode
33 Ignition electrode
36 Temperature sensor in CH flow
52 Solenoid valve 1
52.1 Solenoid valve 2
56 Gas valve CE 427
61 Reset button
135 Master switch
136 Temperature control for CH flow
151 Fuse, slow 2.5 A, AC 230 V
153 Transformer
161 Link
226 Fan
300 Code plug
302 Earth connection
310 Temperature control for hot water
312 Fuse, slow T 1,6 A
313 Fuse, slow T 0,5 A
314 Connector for programmer TA212E
315 Terminal block for programmer
317 Digital display
318 Connector for timer
328 Terminal block for AC 230 V Mains supply
328.1 Link
363 Indicator lamp for burner
364 Indicator lamp 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
6 720 610 601-02.1O
mains supply
r
r
bl
bl
bl
bl
o
o
o - orange bl - black r - red

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Details of the appliance
9
1.9 Technical data
Units Natural gas Propane
Max. rated heat output net 40/30 °C central heating
Max. rated heat output net 50/30 °C central heating
Max. rated heat output net 80/60 °C central heating
kW
kW
kW
29.1
28.8
27.2
29.1
28.8
27.2
Max. rated heat input net kW 27.5 27.5
Min. rated heat output net 40/30 °C
Min. rated heat output net 50/30 °C
Min. rated heat output net 80/60 °C
kW
kW
kW
8.4
8.3
7.4
11.6
11.4
10.5
Min. rated heat input net kW 7.6 10.8
Maximum gas flow rate – After 10 minutes from lighting
Natural gas G20 (HiB = 9,5 kWh/m3)m
3/h 2.9
LPG (Hi= 12,8 kWh/kg) kg/h 2.1
Gas supply pressure
Natural gas G20 mbar 20 -
LPG mbar - 37
Expansion vessel
Charge pressure bar 0.75 0.75
Total capacity l 10 10
Flue
Flue gas temp. 80/60 °C, rated/min. load °C 67/55 67/55
Flue gas temp. 40/30 °C, rated/min. load °C 43/32 43/32
Residual delivery pressure
(inc. pressure drop in air intake duct) Pa 80 80
CO2level at max. rated heat output
CO2level at min. rated heat output
%
%
9.5
9.2
11.3
11.0
NOx-class 5 5
SEDBUK figure, Band A % 90.6 90.6
Condensate
Max. condensation rate (tR= 30 °C) l/h 2.3 2.3
pH-value, approx. 4.8 4.8
General Data
Electrical power supply voltage AC ... V 230 230
Frequency Hz 50 50
Max. power consumption W 101 101
Noise output level dB(A) 36 36
Appliance protection rating IP X4D X4D
Max. CH flow temperature °C nom. 90 nom. 90
Max. permissible operating pressure (CH) bar 2.5 2.5
Permissible ambient temperatures °C 0 - 60 0 - 60
Nominal capacity of appliance l 3.75 3.75
Weight (excluding packing) kg 46 46
Table 2

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Details of the appliance
Condensate analysis, mg/l
Flue system
Elbow - 90 ° Bend - 45 °
Equivalent length 2 m Equivalent length 1m
Gas supply
Ammonium 1.2 Nickel 0.15
Lead ≤0.01 Mercury ≤0.0001
Cadmium ≤0.001 Sulphate 1
Chromium ≤0.005 Zinc ≤0.015
Halogenated
hydrocarbons ≤0.002
Tin ≤0.01
Hydrocarbons 0.015 Vanadium ≤0.001
Copper 0.028 pH-value 4.8
Table 3
HORIZONTAL 100 mm – Standard
Overall Diameter of Duct mm 100
Max.
4 m
Flue Terminal / Duct
Assembly Length
mm 750
Extension Duct Length mm 1000
Table 4
ALTERNATIVE HORIZONTAL 125 mm FLUE SYSTEM
Overall Diameter of Duct mm 125
Max.
13 m
(inclu-
ding
turret)
Flue Terminal / Duct Assembly mm 550
Extension Duct Length - Fixed mm 200
Extension Duct Length - Fixed mm 450
Extension Duct Length - Fixed mm 950
Extension Duct Length - Fixed mm 1950
Extension Duct Length -
Telescopic
mm 265-
375
Extension Duct Length -
Adjustable (Cut to length)
mm 200
Table 5
VERTICAL 125 mm FLUE SYSTEM
Overall Diameter of Duct mm 125
Max.
15 m
Flue Terminal / Duct Assembly mm 1360
Extension Duct Length mm 200
Extension Duct Length - Fixed mm 450
Extension Duct Length - Fixed mm 950
Extension Duct Length - Fixed mm 1950
Extension Duct Length -
Telescopic
mm 265-
375
Extension Duct Length -
Adjustable (Cut to length)
mm 450
Table 6
Total length of gas supply pipe
(metres)
Pipe diameter
(mm)
369
Gas discharge rate (m3/h)
8.7 5.8 4.6 22
18.0 12.0 9.4 28
Table 7

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Installation regulations
11
2 Installation regulations
Gas Safety (Installation & Use) Regulations 1998: All
gas appliances must be installed by a competent per-
son. Failure to install correctly could lead to prosecu-
tion.
The manufacturers notes must not be taken, in any way,
as overriding statutory obligations.
The appliance must be installed in accordance with the
current IEE Wiring Regulations, local Building Regula-
tions, Building Standards (Scotland) (Consolidation),
bye-laws of the local Water Company, Health and
Safety Document 635 (Electricity at Work Regulations
1989) and any other local requirements.
Product Liability regulations indicate that, in certain cir-
cumstances, the installer can be held responsible, not
only for mistakes on his part but also for damage result-
ing from the use of faulty materials. We advise the
installer to avoid any risk by using only quality approved
branded fittings.
The relevant British Standards should be followed i.e.
• BS 6798: Specification for the installation of gas
fired hot water boilers of rated input not exceeding
60kW
• BS 5449: Central Heating for Domestic Premises
• BS 5546: Installation of gas hot water supplies for
domestic purposes
• BS 5440:1: Flues and ventilation for gas appliances
of rated input not exceeding 70 kW (gross): Flues
• BS 5440:2: Flues and ventilation for gas appliances
of rated input not exceeding 60 kW (gross): Air
Supply
• BS 6891: Installation of low pressure gas pipework
installations up to 28mm (R1).
• BS 7074:1: Code of practice for domestic heating
and hot water supply.
These instructions must be followed.
3 Installation
3.1 Important remarks
yAppliance should only be installed in sealed central
heating systems.
yTo avoid gas formation in the system, galvanised radi-
ators or pipes must not be used.
yIf a room thermostat is used: do not fit a thermostatic
radiator valve on the radiator in the primary room.
yAdd a suitable anti-freeze fluid compatible with alu-
minium to the water in the central heating system.
Suitable products are available from Betz-Dearborn
Tel.: [phone] and Fernox Tel.: 01799
550811.
yIn our experience, the addition of sealing agents to
the water in the central heating system can cause
problems (deposits in the heat exchanger). For that
reason we advise against their use.
3.2 Sealed systems
The appliance must not be operated without the system
being full of water, properly vented and pressurised.
The expansion vessel has a volume of 10 litres and is
charged to a pressure of 0.75 bar.
The water capacity of the system is shown in table 9,
page 26. If a greater capacity is required then an addi-
tional expansion vessel must be fitted into the system
return as close to the appliance as possible. The system
pressure can be set up to a maximum of 1.5 bar with 1
bar being the normal setting.
If the system pressure is greater than 2.5 bar when the
appliance is operating at maximum temperature then an
additional expansion vessel must be fitted into the sys-
tem return as close to the appliance as possible.
The filling point must be at low level and arranged as
shown in figs. 5 and 6.
The pressure relief valve is set to operate at 3 bar.
There must be no connection to the mains without the
approval of the local water company. All connections in
the system must be capable of withstanding a pressure
of up to 3 bar and the radiator valves conform to the
requirements of BS 2767:10.
If Thermostatic Radiator Valves are fitted then it is rec-
ommended that one radiator is left open.
yAlways turn off the gas cock before car-
rying out any work on components
which carry gas.
iFixing of the appliance, gas and flue con-
nections, commissioning of the system
and electrical connections may only be
carried out by competent persons author-
ised by CORGI.

6 720 610 596 GB (01.07)
12
Installation
Repeated venting probably indicates a leak and this
must be rectified to ensure the proper operation of the
appliance.
No galvanised radiators or pipes must be used.
If any system water treatment is required then
only products suitable for use with Aluminium
shall be used i.e Fernox- Copal or Sentinal X100,
in accordance with the manufacturers
instructions. The use of any other substances will
invalidate the guarantee. The pH value of the
system water must be less than 8 or the
appliance guarantee will be invalidated.
A drain cock to BS2879 must be fitted to the lowest
point of the system.
IMPORTANT: Check that no dirt is left in the
water pipework as this could damage the
appliance. Thoroughly flush the heating system
and the mains water supply before fitting the
appliance to the wall in accordance with the
recommendations of BS7593:1992.
Fig. 5 Sealed primary water system
Fig. 6 Sealed primary water system - filling method
3.3 Siting the appliance
Regulations concerning the Installation Site
yRelevant national regulations must be complied with
section 3.8.1.
yConsult the installation instructions for details of min-
imum clearances required.
Combustion air
In order to prevent corrosion, the combustion air must
not contain any corrosive substances.
Substances classed as corrosion-promoting include
halogenated hydrocarbons which contain chlorine and
fluorine compounds and are contained in some sol-
vents, paints, adhesives, aerosol propellants and house-
hold cleaners, for example.
Surface temperature
The max. surface temperature of the casing and the flue
is less than 85 °C.
This means that, no special safety precautions are
required with regard to flammable building materials
and fitted furniture. The specified clearences must be
maintained.
Domestic
hot water
Domestic
hot water
Central heating flow Radiator
valve
Lockshield
valve
Central heating return
A drain cock should be fitted at
the lowest point of the heating
circuit and the appliance
Water
main
BS stop valve.
Fixed spindle type
APPLIANCE
Refer to Fig.1
Appliance
water flow
diagram
WRC approved
filling loop
6 720 610 576 -09.1O
Heating
return Non-return
valve Non-return valve
Hose
union Hose union
Test
cock
Temporary hose
Test
cock
6 720 610 576 - 10.1O

6 720 610 596 GB (01.07)
Installation
13
Cupboard/Compartment
The appliance can be installed in a cupboard/compart-
ment need for airing clothes providing that the require-
ments of BS6798 and BS5440:2 are followed. The low
casing losses from the appliance eliminate the need for
ventilation openings in the compartment.
3.4 Wall mounting frame assembly
yTake the wall mounting frame out of the package and
screw together with 6 screws as shown in fig. 7. Use
the inner lugs on the top and bottom horizontal sec-
tions for the appliances that are 440 mm wide.
Fig. 7
yHold the wall-mounting frame against the wall ensur-
ing that it is vertical.
yMark the postion of the flue duct hole if a rear flue is
to be used. Refer to fig. 1 and 15.
yMark the holes for the wall mounting frame onto the
wall, drill and plug the holes and screw the wall
mounting frame to the wall with the screws provided.
Fig. 8
yScrew the pre-plumbing manifold with two screws to
the wall mounting frame.
Fig. 9
3.5 Pre-piping the system
Fig. 10 Manifold
43 CH flow
47 CH return
112 Gas cock
171 Domestic hot water
172 Cold water relief
yA drain tap should be fitted at the lowest point of the
central heating system.
yWRc 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

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14
Installation
Condensate drain
Prepare the condensate discharge system. Refer to
fig. 11. The condensate drainage pipe should be a
standard drain pipe material , i . e. PVC, PVC-U, ABS
etc. and should be at least 22 mm in diameter.
A siphon with a 75 mm condensate seal is fitted within
the appliance.
A connection to an internal drain is recommended.
Any external drain pipe should be insulated to prevent
freezing.
The connection of a condensate pipe to a drain may be
subject to local building regulations.
For more information refer to the CIBSE Guide,
BS5546 and the Building Regulations.
Fig. 11 Position of the condensate drain
3.6 Fitting the appliance
yRemove packing, taking care to observe the instruc-
tions on the packing.
yLie the boiler on its back.
Removing the outer case
yTurn the clips with a screwdriver (1.).
ySlide the outer case upwards and then forwards to
remove (2.).
yRemove the plastic caps from the boiler connections.
Fig. 12
Fixing the appliance
yFit the washers onto the gas and water connections.
yLift the boiler onto the wall-mounting frame. The lugs
pass through the rectangular holes in the boiler back
panel.
yTake care not to disturb the washers on the connec-
tions.
6 720 610 602 - 03.1O
Benchmark: For optimum performance
after installation, this boiler and its asso-
ciated central heating system must be
flushed in accordance with the guide-
lines given in BS5793:1992 “Treatment
of water in domestic hot water central
heating systems”.
iThe outer case is secured against unau-
thorised removal by two clips (electrical
safety).
Always secure the outer case with those
clips again after refitting.
1.
2.
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6 720 610 596 GB (01.07)
Installation
15
Connecting the flue duct
yFit flue duct connector onto appliance flue spigot.
ySecure with the two screws supplied.
Fig. 13
yFor remaining installation of flue assembly, refer to
the relevant installation instructions.
3.7 Checking the connections
Water connections
yCheck that the O-rings or seals are in place before
tightening the connection.
yTurn on the service valves for central heating flow
and return and fill the heating system through a WRC
approved filling loop.
yCheck all seals and unions for leaks (testing pressure
max. 3.0 bar as indicated by pressure gauge).
yTurn on cold water service cock and fill hot water sys-
tem (testing pressure max. 10 bar).
yCheck all connections for leaks.
Gas supply pipe
yCheck that the seal is in place before tightening the
connection.
yTurn off gas cock to protect gas valve against
damage from excessive pressure.
yCheck gas supply pipe.
yRelease the pressure on the gas supply pipe.
3.8 Flue Systems
The only flue systems that may be used are those sup-
plied by Worcester Heat Systems.
The flue system must be installed in accordance with
the requirements of BS5440:1.
Standard 100 mm flue system
The standard concentric flue system provides for a hor-
izontal length of upto 4 m. Full instructions for fitting this
flue are in Subsection 3.8.2 “Installation of the flue”.
Alternative 125 mm diameter flue systems
Installation instructions for the alternative flue systems
are sent with the appropriate flue kit.
Systems are available to give a maximum horizontal
length of 13 m.
A vertical flue system upto a height of 15 metres is avail-
able.
45° and 90° flue bends can be used with a correspond-
ing reduction in flue length of 2m for each 90° bend and
1 m for each 45° bend used.
IMPORTANT: Any horizontal flue system fitted to a
condensing boiler must incline towards the appliance at
an angle of 3 % (30 mm per metre length) to prevent
condensate dripping from the flue terminal. This
means that the clearance above the appliance
must be increased to match the duct length.
Refer to fig. 1 on page 5.
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1
3
2
4

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16
Installation
3.8.1 Siting the Flue Terminal
The flue must be installed in accordance with
BS 5440:1 and the Building Regulations. Flue terminals
in carports and under balconies are to be avoided.
The terminal must be positioned so that it does not
cause an obstruction nor the combustion products a
nuisance. See fig. 14 and table 8.
The terminal will, at times, give out a plume of water
vapour and consideration must be given to this when
choosing a terminal position. Keep clear of security
lighting, activated by passive infra-red sensing heads.
If the terminal is less than 2 m above a surface to which
people have access then a guard must be fitted. The
guard must be evenly spaced about the terminal with a
space of 50 mm in each direction and fixed with plated
screws.
A guard Type K2 for the standard horizontal flue, can be
obtained from Tower Flue Components, Vale Rise, Ton-
bridge TN9 1TB.
Fig. 14
Minimum dimensions of flue terminal positions (all types) (see fig. 14)
Dimension Terminal Position (kW input expressed in net) Balanced flues room sealed: Fanned draught
A1) Directly below an opening, air brick, opening windows, etc. 300 mm
B 1) Above an opening, air brick, opening window, etc. 300 mm
C 1) Horizontally to an opening, air brick, opening window, etc. 300 mm
D Below gutters, soil pipes or drain pipes 75 mm
E Below eaves 200 mm
F Below balconies or car port roof 200 mm
G From a vertical drain pipe or soil pipe 150 mm
H From an internal or external corner 300 mm
I Above ground roof or balcony level 300 mm
J From a surface facing the terminal 600 mm
K From a terminal facing the terminal 1200 mm
L From an opening in the car port (e. g. door, window) into the dwelling 1200 mm
M Vertically from a terminal on the same wall 1500mm
N Horizontally from a terminal on the same wall 300 mm
O From the wall on which the terminal is mounted Not applicable
P From a vertical structure on the roof Not applicable
Q Above intersection with roof Not applicable
Table 8
1) In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the pur-
pose of accommodating a built-in element such as a window frame.

6 720 610 596 GB (01.07)
Installation
17
3.8.2 Installation of the flue
The standard 100 mm diameter horizontal flue system is
suitable for lengths upto 4 m.
Flues upto 650 mm do not require an extension duct
assembly.
Flues between 1600 mm and 4000 mm require exten-
sion duct assemblies.
NOTE: Flue lengths between 650 mm and 730 mm
cannot be accomodated. Refer to fig. 16, 17, 18.
Standard system comprise: Flue turret - Flue turret
clamp - Terminal assembly - Wall sealing - plates.
Extension kit comprises: Air duct - Flue duct - Duct
clamp. Refer to fig. 19.
Instructions for fitting other flue systems are packed
with the relevant flue kit.
Check that the position chosen for the appliance is sat-
isfactory. Refer to fig. 15.
Fig. 15 Marking the position of the side flue opening
Fig. 16 Standard Flue
Appliance
120
Drilling point for
flue duct opening
3 %
(30 mm/meter)
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 - 07.1O
Flue
Turret
No
Clamp
Maximum 650 mm
Terminal
Assembly
Outer
Wall
6 720 610 602 - 08.1O

6 720 610 596 GB (01.07)
18
Installation
Fig. 17 Flue with one extension
Fig. 18 Flue with extensions
Fig. 19 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

6 720 610 596 GB (01.07)
Installation
19
3.8.3 Flue duct preparation and assembly
Measure the flue length L. Refer to fig. 20, 21.
Fig. 20 Flue length - rear
Fig. 21 Flue length - side
Mark off the lengths shown onto the ducts and cut to
length. The cuts must be square and free from burrs.
Terminal assembly outer (air) duct - L-750 mm, inner
(flue) duct - L- 50 mm.The measurement is made from
the ridge at the terminal indicating the outer face of the
wall. Refer to fig. 22.
Extension air duct - L-70mm, flue duct - L-50 mm.
The measurement is from the formed end.
Fig. 22 Flue terminal position
Assemble flue system completely. Push the ducts fully
together and clamp in the positions. The slope of the
terminal outlet must face downwards.
The assembly will be made easier if a solvent free
grease is lightly applied i.e Vaseline, to the male end of
the ducts.
NOTE: An inner wall sealing plate is provided
which should be fitted to the ducts before assem-
bly.
Push the assembly through the wall and fix the turret to
the appliance with the clamp. Refer to fig. 23.
Fig. 23 Flue turret
Ensure that the turret is fully entered into the socket on
the boiler. From the outside fix the outer wall plate to the
terminal and, after ensuring the duct is properly i nclined
towards the boiler, fix the plate to the wall.
If the terminal is within 2 m of the ground where there is
access then an approved terminal guard must be fitted.
The guard must give a clearance of at least 50 mm
around the terminal an be fixed with corrosion resistant
screws.
NOTE: THE FLUE MUST BE INCLINED TO THE
BOILER
L
120
6 720 610 602 - 12.1O
NOTE: THE FLUE MUST BE INCLINED TO 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

6 720 610 596 GB (01.07)
20
Electrical connections
4 Electrical connections
All control and safety systems are built into the appli-
ance.
yAllow mains cable to protrude at least 50 cm from
wall.
yTo make splash-water proof (IP): cut the cable grom-
met hole size to match diameter of cable, see Fig. 26.
It must be possible to isolate the appliance. The appli-
ance must be earthed.
The appliance must be connected to the mains through
a 6 A double pole isolator with a contact separation
3 mm in all poles and supplying the appliance and con-
trols only. The wiring must comply with the current
requirements of the IEE Wiring Regulations and any
local regulations which apply.
• Supply: 230 V ~ 50 Hz, 140 Watts
• Mains cable: PVC insulated 0.75 mm2
(24 x 0.20 mm) to BS6500-Table 6.
Temperature rated 100 °C.
• Protection IPX4D
• External fuse 3 A.
4.1 Connecting the appliance
To gain access to the mains connection remove the
drop down facia cover. The drop down cover is
removed by lowering it to the horizontal position and
pushing firmly upwards at the rear of the supports to
release the cover. Lift cover from the appliance.
After installation (or in the event of an electrical fault) the
electrical system shall be checked for short circuits,
fuse failure, incorrect polarity of connections, earth con-
tinuity and resistance to earth.
yPull out cover panel at the bottom and remove. Refer
to fig. 24.
Fig. 24
yRemove screw and slide terminal cover forwards to
remove. Refer to fig. 25.
Fig. 25
yAlways disconnect the power supply to
the appliance at the mains before carry-
ing out any work on the electrical sys-
tems and components.
0
1
2
34
5
E
6 720 610 332-10.1R
0
1
2
34
5
E
6 720 610 332 -11.1
R