Chaffoteaux & Maury STERLING PP User guide

STERLING PP
Room SeaIed Fanned Balanced Flue
Combination Boiler
GAS SAFETY (INSTALLATION AND USE) REGULATIONS.
It is the iaw that all gas appliances are installed by a competant person
in accordance with the above regulations
(For use on natural gas only. GZO)
G.C. No 47 980 07
from serial number 495 089 010 - 32.
CC
Installation and
Servicing Instructions
(leave these instructions with the user)
Looking Good.Heating Better
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

CONTENTS
HealthandSafetyinformation
1
1. INTRODUCTION
1.
1.1.
12.
1.3.
1.4.
1.4.1. .
1.4.2.
1.4.3.
1.5.
1.6.
1.6.1.
1.61
1.63.
1.6.4.
1.65.
1.6.6.
l-6.7.
Generaldescription,specialfeatures.guarantee
DimensionsFig. 1
TechnicalData
clearances
Wall thickness
Rearflue outletFig. 2
SideflueoutletFig. 3.Fig.3a.Fig. 3b
OtherfluearrangementsHorizontalFig. 3c
Descriptionof componentsandlocationFig. 4
Descriptionof operation
CentralheatingFig. 5
Hot waterFig. 6
Gas(alsosee2.7)
Functionalflow diagramFig.7
Safetycontrols
Functionalflow wiring diagramFig. 8
Illustratedwiring diagramFig.9
2. INSTALLATION REQUIREMENTS
2.1. General
2.2. Location
23. Watercirculationsystem
2.4. Sitingtheflue terminalFig. 10
2.5. Air suppiy
2.6. Elecaicaisupply
2.7. Gassupply
3.
SYSTEM GUIDANCE
3.1. General
32 Systemcontrols
3.3. BumpFig. 11
3.4. Expansionvessel
3.5. Mainswaterconnection
3.6. Fiig andrechargingFig. 12.Fig. 13(page12)
3.7. Makeupsystem
3.8. Pipzwork
3.9. Domesticexpansionvessel
39.1. Boilerreplacement
3.9.2. Existingsystems
3.10 Cylinder
3.11 Inhibitorsandwaterconditioners
3.12 Add ondevices
3.13 HeatingandhotwatersystemsFig. 14,Fig. 15.Fig. 16.Fig. 17
3.14 ShowerapplicationFig. 17a
2
2
3
3
3
4
4
4
5
6
6
6
7
7
7
8
8
9
9
9
9
10
IO
10
10
11
11
11
11
11
11
11
11
12
12
12
12
12
13
14
(4
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

CONTm (cant)
4. INSTALLING THE BOILER
Page.
4.1.
4.2.
4.3.
4.4
4.5.
4.6. .
47
4.8.
4.9.
4.10.
4.11.
4.12
4.13.
Generalinformation
PositioningtheboilerFig. 18
Rearoutletflue Fig. 19
Sideoutletflue Fig. 20
JigplateFig. 21
GasandwaterconnectionsFig.22
Waterconnections
Gasconnection
Fitting theboilerFig.23
Fitting thesafetyvalveFig.24
Fitting theflue (upto700mmlong)Fig. 25
Fitting theflue (over700mmlong)
ConnectionthepressureswitchFig. 26
ElectricalconnectionsFig.27
5.
EXTERNAL CONTROLS
5.1. Timeclock - TimeclockandroomstatFig. 28 19
5.2. Timeclockandzonevalves(springreturn)Fig.29 19
53. ProgrammerandzonevalvesFig.30 20
5.4. Honeywell& SatchweilcontrolledzonesFig. 3I 20
5.5. FrostthermostatFig. 32 20
6.
COMMISSIONING
6.1. Hotwatercircuits.filing Fig. 33 21
62. Centralheatingcircuits.filling, Fig. 34 21
6.3. Lighting theboilerFig. 35 21
6.4. GasrateadjustmentFig.36.Fig. 37,Fig. 38 22
6.5. D.H.W. flow rateadjustment(seealso6.7.Fig. 39a) 23
.6.6. Adjustingtheheatingsystemby-passFig. 39 23
6.7. D.H.W. flow rateadjustmentFig. 39a 23
6.8. PumpswitchingadjustmentFig.39b 23
6.9. Fitting thecasingFig.40 24
7. ROUTINE SERVICING
7.1.
7.2.
7.3
7.4.
7.5.
7.6.
7.7.
Generairequirements
To removefront casingFig.41
ToremovecombustionchamberFig.42
ToremoveburnerassemblyFig.43
Toremovepilot Fig.44
Tocleanheatingreturnfilter Fig.45
Cleaningandreplacementof parts
Tocheckoperationof safetyvalveFig.46
15
15
15
16
16
16
16
16
17
17
17
18
18
18
25
25
25
26
26
26
27
27
(4
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

(cant)CONTENTS
Pace.
8. REPLACEMENT OF PARTS
8.1.
82.
8.3.
8.4.
8.5.
8.6.
8.7.
8.8.
8.9.
8.10.
8.11.
8.12.
8.13.
8.14.
8.15.
8.16.
8.17.
8.18.
8.19.
8.20.
821.
8.22.
823.
824.
8.25.
8.26.
827.
8.28.
8.29.
8.30.
8.31.
8.32.
8.33.
8.34.
ToremovethermocoupleFig.47.Fig.48
ToreplaceelectrodeandleadassemblyFig.49
To repiaceoverheatthermostatFig.50
Toreplaceignition microswitchFig. 51
To replaceC.O.V. microswitchFig. 52
Toreplaceflow switchassemblyFig. 53
. ToreplaceventuriFig. 54
ToreplaceprimaryheatexchangerFig.55
ToremoveelectricalcontrolboxFig. 56.Fig. 56a(page33)
ToreplacepumpheadFig. 57
ToreplacechangeovervalveFig.58.Fig. 58a(page34)
ToreplacesecondaryheatexchangerFig.59
To replaceair separatorFig. 59a
ToreplaceboilerthermostatFig.60
Toreplaceboilerlimit thermostatFig.61
ToreplaceD.H.W. thermostatFig.62
ToreplacesparkgeneratorFig.63
ToreplaceP.C.B.Fig. 64ElectricalboxlayoutFig. 65
To replacetherm0electricvaiveFig.66
To replacesolenoidvalvesFig. 67
ToreplaceheatingbodyliningsFig.68
ToreplacefanassemblyFig.69
ToreplacepressureswitchFig. 70
Tom-pressuriseexpansionvesselFig. 71
ToreplacepressuregaugeFig. 72
ToreplacethedomesticexpansionvesselFig. 73
To repiacemainburnerFig.74
To replaceburnermanifoldassemblyFig. 75
Toreplacepiiot injectionFig. 76
ToreplaceexpansionvesselFig.77
ToreplaceviewingwindowFig .78
ToreplacemaingasvalvebodyFig.79
ToreplacethethermometerFig.80
ToreplacesafetyvalveFig. 81
9. FAULT FINDING
9.1. Logic sequence
9.2. Centralheatingoperation
9.3. Domestichotwateroperation
9.4. Faultfinding tabularchart
28
28
28
29
29
29
30
30
30
31
31
32
32
33
33
33
34
34
35
35
35
35
36
36
36
37
37
37
38
38
38
39
39
39
40
41
42
43
SHORT SPARE PARTS LIST
Rearcover
(iii)
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

CO&TRO
COF SUBSTANCE HARMFUL TO HEALTU
PORTANT
To comply with the Conuoi of SubstancesHarmful to Health Regulation 1988we are required to
provideinformation onthefollowing substancethat iscontainedin this appliance.
CombustionChamberLining
bLia&al
Alumina SiliconeFibre
During servicing, keep the dust generation to a minimum and avoid
inhaling anydustand contact with the skin andeyes.Normal handling
andusewill not presentany discomfort. although some people with a
historyof skincomplaintsmay be susceptibleto imitation.
When disposing of the lining ensure that it is securely wrapped and
washhandsaftercontact.
1
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

...
L INTRODUCTION
The STEELING PP is a waii mounted. low water content
fanned balanc& Bue appliance suitable for central heating
and hot water via a non storage waler lo water heat
fachanger. The maximum output is 23 kW (78460 Btwh).
The boiler is designed for sealed systems only and included
in the appfiance is the expansion vessel. circulating pump,
temperature and pressure gauges. safety valve. electric
connection box. and domestic expansion vessel.
The standard tlue assembly supplied with the boiler is
100 mm (4 in) dii pip. CM be directed to the rear or to
the left or right and can be extended to a maximum
length of 3 m. or 1.6 metres horizontally using the avai-
lable 90” bend (see sections 1.4.1. 1.4.2 and 1.4.3
figures 2.3.3a. 3b. 3~).
Special featurestndude :
- Output to central heating fully range rated between
l/3 and fuil output.
- High efficiency.
- Specialjig plate enabling all pipework io be instai-
led before instailing appliance.
- Independent control over central heating Bow tem-
perature and hot water.
- Fully adjustable central heating flow temperature.
- Regulation between 50” Cand 62” C.
- High limit thermostat for both boiler and hot water.
- Water flow switch to protect appliance.
- Suitable for showers with compatible mixer valves.
G-tee -
The manufacturer’s guarantee on this appliance is for 12 months from the -iate of purchase. The guarantee is void. if the
appliance is not installed in accordancewith the recommendations made herein.
,
1.1
Fg. 1
REARounEr
FLUE
SIDE OUM
FLUE
A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
mm
820.5
391.0
365.0
100.0
169.5
654.5
43.0
50.0
75.0
260.0
150.0
972.5
13.0
61.0
30.0
152.0
112.0
in
32.3
15.4
14.4
4.0
6.7
25.7
1.7
2.0
3.0
10.2
6.0
38.3
0.5
2.4
1.2
6.0
4.4
2
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

... Technical Data
Eatmta
Input........................................... 28.90 kW 98612 Btwh
output ........................................ 23.00 kW 78480 Btuh
Water5ow raised
45 “C (81 "D .............................. 7.4 bin 1.7 gahin
Waterflow raised
35 “C (63 "D .............................. 9.5 vrnin 2.1 galhin
Waterflow raised
30 “C (54 OFI.............................. 11.1 Ymin 2.5 @hnin
Maximum temperature.. ............. 60 “C 140OF
Maximum pressure..................... 10bar 150psi
hfinimurn wo*g pressure.. ...... .6 bar Qpsi
Gasme ...................................... 2.743 m%h 96.87
R3/h
Bumer pressure.......................... 11.8 mbar
4.7 in wg
Central heating
hbximum input .......................... 27.64 kW 94313 Btwh
Maximum output.. ...................... 22.00 kW 75068 Btuh
Gasmte (maximum). .................. 2.63 m%‘h 92.98
A3h
Burner pressure.......................... 11.2 mbar 4.5 in wg
Minimum input.. ......................... 10.85 kW 37020 Btu/h
Minimum output......................... 7.64 kW 26062 Btuh
Gasrate (minimum) ................... 1.OmJ/h 35.31
R3/h
Burner pressure.......................... I .5 mbar 0.6 in wg
Minimum flow me ..................... 3OOm 1.1galmn
Maximum pressure..
................... 2s bar 36.5 psi
NaturaI gas
Manifold injectors 14of.. ............ 1.28mm 0.05 in
Filot injector................................ 0.3 mm 0.01 in
Gassection restrictors 2i3 valves 4.4 mm 0.17 in
l/3 valve.. 2.3 mm 0.09 in
- I
,
conoatioo8
Gas._.....
....................................................... 22mmcopper
Heatingilow ................................................ =mcopper
Heatingreturn.............................................. x=ncopper
Mainscoid water inlet .................................. 15mmcoppef
Hot water outlet ........................................... 1s mrncopper
Electricalsupply 240 V - 50 Hz. fused at 3A
Electricalconsumption ................................. 195 watts
IntemaiQ fused. two at 2A (BS4265)
weight ......................................................... 42 kg 92.4Ib
Watercapacity ............................................. 4 litres 7 pints
Ignhh - Anstoss continuous spark generator
EIectmde - Chatkteaux et Maw-y Ltd. spark gap 5 mm
Bofla thamosmt - EGO,lMlT (82°C)
Boila iknit thermostat - SOPAC/JAEGER(85°C)
Hot wata fitnit thermostat - SOPAC/JAEGER(57°C t 3°C)
Safety overheat thertnosmt (Tokoswitch - (105”C-l
klmwood - (105”O
Guvahw -AEMF
Fan motor - SEL
Pressure switch - DUNGS 102 Pai 55 Pa
Pump head - GRUNDFOSUP 15160
c.Eexpa&n~initial&~gep1wsm-0.6Sbar(9.6psi~
Domestic,a&~nvess&ithfch~gcprarmr-2bar(30psi)
1.3 lvIfaimrrm Clearances around Boiler
Top above air duct .......... somm (2il-l)
Bottom below case..
........ 15Omm (6in)
Sides............................... 1wmm (4in)
Front.. ............................. 600mm (24 in)
1.4 Wall Thicknesses
The standard flue assembiy can accomodate the following thicknesses.
Rear:h-n55mmto576mm
Side : from 55 mm to 392 mm
(this allows for a minimum clearanceof 100mm between the appliance and the side wall. As this dime&On
increases.so the maximum sidewail thicknessavaiiabledecreases).
Extension flue assemblies are availableto accomodatewail thicknesses of :
Rear: hn-n 577 mm to 2876 mm
Side : from 393 mm to 2692 mm
Seefigs. 2 and 3 for details of number of extensions required.
IMPORTANT NOTE : The extension ducts supplied. up to a maximum of 3. will in factpermit a greaterlength than
indited to be covered. The ducts MUSTbe cut so that the maximum length from the centreline of the flue turret to
the outermost point of the air duct DOESNOT FXCEED3 metres horizontal. Greaterlengthmust not be used.
Seesections 1.4.1. 1.4.2. 1.4.3.
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

...
1.4.2 Side Fke Orrtfet Horizontal
A0.l SlDEDIJTLETASSEMBLY
Fig.33
PLASTIC AIR DUCT
1.4.3
Rear FIae Outlet Horizontal
To cat flat assembly to length
- Measure wall thickness tn.
- Add 74 mm. this wiii give required length (L).
- hiark plastic air duct for length (L) and cut off
surplus (from piain end).
N.B. If extension sections are used ensure these are
6rmiy pushed together. see fis. 3b and 3c and a faIIof 5
mm per metre length should be provided (see section
- Cut off same amount from aluminium flue duct
flueexreneionfrcceesofy
Paft No. 82823.00
REAR OUTLET ASSEMBLY
To cat flae usaubtp to length
- Measure from external walI faceto centre line of
appliance and substract 37 mm (this will give
required length “L”).
- Cut off surplus from plastic air duct (plain end).
N.B. If extension sections are used ensure these are
fitmiy pushed together. see figs. 3b and 3c and a tXI of 5
mm per metre length should be provided (see section
Flueextensionaccessory
- Cut off same amount from
Pefl No. 62623.00
akuninium flue duct (plain end).
(GC.264459)
(1meuelength)
Other flue Arrangements Horhontal
*
“OE
.-E
9%
OE .
1 2
.-
Fig. 3c
1. Distance from internal comer 300 mm without
kit.107 mm with kit No 76216 (GCNo 264 833).
2. Distance beIow balconies or eaves 200 mm
without kit, 107 mm with kit No 76216 (GCNo
264 833).
3. Appliance is normally supplied packed with
standard 650 mm staight flue section. Additional
straight extension lengths of 1 metre, part No
62823 (GCNo 264 459). can be use up to a total
straight length of 3 metres. It is also possible to
incorporate one bend in the Bue using part No
65572 (GCNo 264 835). In this case the length
Ll + 12 should not exceed 1.6 metres
horizontaily.
4
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

1.5 Description of Components and Location
6
27
19 li i8
Fig. 4
The applianceis mounted in a steelcasewhich has a
white epoxy resin paint f&h.
1. chaarir:
The chassisis a rigid plated mild steel pressingon which
alIcomponents are mounted.
2. PIue hood:
Is an ahknium alloy casting onto which the two speed
fan is mounted.
3. comhuation chamki:
Thk is assembled kern a number of components
mounted onto the chassis. The front panel is simply
removed for servicing complete with the expansionvessel,
ahook is fitted below the appliance to acceptand retain
the panel during servicing.
4. EqJanrion veuch
The expansion vessel has a capacity of 5.4 litres (1.19 gal)
and is stied for a .normai system water contentwhere the
toadis equivalent to the maximum output of the boiler.
The chargepressure is 0.65 bar.
5. Pilot uwrity is by thermocouple flame f%.ue.
6. Multigas borner comprh&g: stainless steelblades(14)
and a manifold with injectors (14).
7. Gasaation induding thermoelectric valve and two
stagesolenoid valves.
8. Saondaq hut erchanger :
The secondary heat exchanger is a plate type heat
exchanger. A thermostat is litted on the pipework limiting
the domestic hot water temperature to a maximum of 57
do c.
Q.c6pzL8cOVUV8fVC:
Thevalve is activated by a demand for domestic hot
water, doses the heating drcuits, and directswater to the
secondary heat exchanger.
lO.EIairidal box containing :
Mains connection
Fuses
Printed circuit board
Conneaions for extemal controts
Connections for fan. pressure switch and flow switch
Connections for pump
Connections for change over valve and for gassolenoid
Wve
11. Solenoid v&e I
Blcck on which 3 valves are mounted :
l/3 valve -1st stage valve-heating and hot water (blue)
- .:5-~e- full output to hot water (black)
,-
2’3 valve - ,i?ariablevalve) centi heating (orange)
12. C~rEldfOS pump motor
13. Air aepaxtor and vent directly connected to the pump
inlet (not illustrated).
14. Regdation saew to adjust output to heating (u3
valve).
15. Hutiug body compriring :
Copper tinned tube heat exchanger proteaed with silicone
resin paint Combustion chamber in aluminium coated
steeLCombustion chamber iining - Ceramic fibre paneis.
16. High Emit thcmnostat
17. Water remice t8p (not illustrated).
18. Flow iroktfng valve - heating (not illustrated).
19. Gasr&r tap (not illustrated).
20. Domestic hot umet outIe( with regulator (not
illustrated).
21. Safety vaIve with dmin tap (not illustrated).
22. Heating mua idating vahm with filter (not
illustrated).
23. Ignition button.
24. Thumomaer irldicatlng boiler flow tempemture.
25. Purr.
26. Selector switch - hot water on&/OFF/heating and hot
water.
27. lbenaosm to regulate heating tlow temperature.
28. Presrrur gauge.
29. Prcrr~rr stich (not illustrated).
30. Domestic expansion versei (not ilIustmted).
31. Water flow swieh (not illustrated).
32. Data badge position.
5
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

...
1.6 Description of Operation
The appliance is combination boiler providing central
heating and hot water. Hot water is provided on a
demand bask For the duration of the demand for hot
water the central heating is intemrpted.
The appliance operates in two modes. A hot water onky
setting where it operates only on hot water demand
and a hot water:+ central heating setting providing
central heating and switching to hot water on demand.
1.6.1 CentA Hat@ (seefq. 5)
‘fhe pump (21) circulates water which returns to the
The limit themxntat (16) setto 85” Ccloses both soie-
boiler via the return valve (31) which incorporates a fd-
ter (30). Before reaching the pump it passes through an
air separator and air purger (17). The return water
passesthrough the heat exchanger(2) where it is hea-
ted. It then passes through the changeover valve (19)
which in heating mode is in its rest position and out via
the flow wlve (27) to the radiator ckcuits (34).
The boiler thermostat (8) controls the temperature of
the circulation water between a minimum of 50” C
approx and a nominal maximum of 82” C. The boiier
thermostat also controls the opening of the l/3 (11)
and variable solenoid valve (10).
1.6.2 Hot Water (see fig. 6)
When there is a demand water flows in from the cold
mains supply (26) through the water section part (35) of
the change over valve (19). The indusion of a venturi (24)
produceshi4 pressure under the diaphragm (23) causing
it to rise. This movement is transmitted to the changeover
valve dosing the heating port and opening the hot water
port, as shown (20). The primary water heated by the
baiter now passes through the water to water heat
exchanger (18) where it flows through alternate plates
indiicUy heating the DHW.
A domestic exoansion vessel is fitted in the D.H.W. circuit
(36). ’
The rising of the changeover valve spindle causes:
1. The opening of a microswitch stopping the pump.
This circuit is remade by a second microswitch making
when the hot water port is fUnyopen.
2. The by-passing of the boiler thermostat brings the
boiler under control of a fixed temperature thermostat
(32) which operates on the 2/3 f=ed solenoid (12).
lhe D.H.W. flow rate is adjustable by a restrictor (25) and
a limiting thermostat (32) reduces the gas rate when the
domestic hot water reaches 57°C by interrupting the
electricalsupply to the hot water solenoid (12).
If the primary circuit reaches85°C the limit thermostat (16)
doses both solenoids valves.
noids vatves in the event of its set temperature being
reached as could occur under the low tlow conditions.
The boikr is protected by a high limit thermostat (4)’
the operation of which intemrpts the thennocoupie and
extinguishes the pilot. If the hiih limit thermostat op-
ratesit is necessary to manually re-establishthe pilot.
An expansion vessel (13) is fitted in the primary circuit.
Central Heating Hot Water
16
Fig. 6
6
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

1.6.3 Gas (see figs. 5 and 6)
When the ignitor button is siowiy released gasis admitted
to the underside of the solenoid valves (10.11 and 12).
When the main gas tap (33) is turned to the on position
gas is admitted to the gassection (7). Pressingthe ignitor
There are 3 solenoid valves: the centre (blue) valve (11)
button (9) operatesamiuoswitch causingthe commence- frxed at l/3 of max rated output the right hand hot water
ment of a firing cyde. The fan changes from low to hiih (black) Wve (12) fzed at 2/3 of maximum rated output.
speed and aRer a purge period of approx 14 seconds a the left hand central heating (orange) valve (10) which is
axMinuous stream ot sparksare delivered lighting the pilot variable up top 2/3 maximum rated output. The gas
@is (3). Simukaneouslv the thermoelectric vaive (14) is admitted by the orange valve is varied by adjuster (6) (see
opened and after a further 5 seconds sufficient energy is seaion 6.4).
king produced by the thermocouple (5) for the thermo-
electricvalve to beretainedin the open position.
1.6.4 FUNbIONAL FLOW DIAGRAM
Fig. 7
““‘” “--’ 1 Generator-
Fan
t-hgh
Soeed
L
SO02
I
1Domssoc ] 1 Heatii 1
limit
I
Thermostat Limit Thermostat
WI
Boiler 82%
Control
Thermostat
1.6.5 Safety Controls
Should the central heating water flow reduce to beloW300
In addition to the normal safety controls the appliance Vh(1.1 gal/min) the gas suppiy to the burner is turned Off.
incorpomtes the following feature. seefq. 4 (31)
and figs. S&6 (37).
7
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

1.6.t
1.6.7
RYNCTIONAL FLOW
WIRINGJXlLGRAM
PRINTED CIRCUIT BOARD
ORANGE
BLUE
BLACK
BROWN
RED
VIOLET
WHITE
GREY
Rg..8
ILLIISTRAIED WIRING DIAGRAM i
W
AU CABLES ARE 240V EXCEPT WHERE THEY ARE INDICATED 24V GR
FAN i-m1
- CHANGE OVER VALVE
SOLENOIDVALVE
213 li33
r
f
>
8
SPARK GENERATOR IGNITION BUllON
WATER FLOW
SWITCH
Fig. 9
8
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

2
INSTALLATION REQUIREMENTS
2.1
General
?-heinstalIation of the boiler must be in accordance
with Gas Safety (Installation and Use) Regulations.
Buildiig Regulations and current Byefawsof the Local
Water Undertaking. It should be in accordance also
with the current B.S. Codesof Practiceand the British
Gas Specifications for Domestic Wet Central Heating
Systems and any relevant requrrements of the iocai
Gas Region. Local Authority Building Standards
(Scotland) Regulations. and the SafetyDocument 635.
The Electridty at work Regulation.
Detailed recommendations are stated in the fotlowing
British Standard Codesof Practice:
B.S. 6891.B.S. 6798. B.S. 5440 : 1and 2. B.S. 5449: 1.
B.S. 7593. BS 5546 B.G.DM2.B.S. 4814. B.S.7074 1
e 2. B.S. 7671.
2.2
Note : Gas Safety (Installation and Use) Reg. It is the
law that all gas appliances are installed by competant
persons in accordance with the above regulations.
Failure to install appliances correctiy could lead to
prosecution. It is in your own interest and that of
safety to ensure compfiance with the law.
LOCZitiOXl
The boiler is not suitable for external installation. The
position chosen for the boiler must permit the
provision of a satisfactory flue termination. The
location must also permit adequatespacefor servicing
and air circulation around the boiler. The surface on
which the boiier is mounted must be of non
combustible material.
The boiler may be installed in any room or internal
space although particular attention is drawn to the
requirements of the current B.S. 7671 and. in
Scotland, the electrical provisions of the Building
Regulations applicable to Scotland.with respectto the
installation of a heater utilising mains electricity in a
room or internal spacecontaining a bath or shower.
Where the installation of the boiler will be in an
unusuaf iocation specialproceduresmay be necessary
and BS 5546 givesdetailed guidanceon this aspect.
A compartment used to enclose the boiler must be
designed and constructed specikaUy for this purpose.
An existing cupboard or compartment may be used
provided that it is modified for the purpose.
Details of essential features of cupboardkompart-
ment design are given in BS6798.
2.3
Water Ckulation System
The appliance is suitable for SEXED SYSTEMSONLY
and should be installed in accordance with the
relevant recommendations given in BS 6798. BS
5449:l (for the smallbore or/and microbore systems)
and the British GasSpecifications for Central Heating
systems.
2.4
Siting the Fhe Terminal
Refer to section 1.4 for details of wail thicknesses
which can becovered
Detailed recommendations for ffueing are given in BS
5440 Pt 1. The following notes are intended to give
generalguidance.
The boiler must be installed so that the flue terminal is
exposed to external air. The boiler must NOT be
installed so that the terminaf discharges tnto another
room or spacee.g cuthouse or closed in lean-to. It is
important that the position of the terminal allows a
free passageof air across at all times. The minimum
acceptable clearances from the terminal to
obstructions and ventilation openmgs are specified
below (fig. 10).
Horizontal FItre
Termid posaions Minckallulces
A - Direuly below an opening. windows etc
or adjacentto an opening ...................... 300 mm
B - Below gutters soil pipes or drain pipes... 75 mm
C - Bebw eaves.._....................................... 200 mm*
D - Below balconiesor car port roof ......._....200 mm’
E - From a verticaldrain pipe or soil pipe .... 75 mm
F - From an internal or external comer ........ 300 mm*
G - Above ground roof or balcony level ....... 300 mm
H - From a surfacefacing the terminal ......... 600 mm
J-Fromanopeninginthecarport
(e.g. door or window) into dwefiing ........1200 mm
K; Vertioaityfrom a terrninai on the same
.......-......................................-......... 1SOOtllnl
L - Horizontally from a terminal on the
samewall .............................................. 3oomm
l (107 mm) minilnlnn clearanceusing
kitNo. 76216.00(G.C.264 833).
9
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

BUILDING REGUIADONS excerpt.
Aqcoved document JPartB 1.4 (0 (D).
Q Protect with a tem%nai guard ftited centraiiy over
the terminal if it could come in contact with people
near the building or be subjected to damage.
D) Designed so as to prevent the entry of any matter
which might restrict the flue.
(A terrniruti guard G.C.NO381 782 is availablefrom).
Quinnei Barret 8 Quinnel Wireworks
Old l&t Road
London SE15 lNL TeL [phone]
The air inlet/outlet duct and the terminal of the
appliance must not be closer than 25 mm (1 in) to
any combustible material. Detailed recommendations
on the protection of oambustiabie materiai are given
inBS544oPtl.
MPOXIlSNI NOTICE : IRdBBR FRiWBD HOUSES
IFTHEAPPLIANCEISTOBEFITTEDINATIMBER
FRAMED BUILDING IT SHOULD BE FITTED IN
ACCORDANCE WITH THE BRITISH GAS
PUBLICATION - “GUIDE FOR GAS INSTALIATIONS IN
TIMBER FRAMED HOUSING’ reference DM2. IF IN
DOUBT, ADVICE MUST BE SOUGHT FROM THE
LOCALREGIONOF BRITISHGASORC.O.R.G.I.
2.6 =s=PPlY
The room in which the boiler is instaiied does not
require a putpose provided air vent
Ifthe boiler is installed in a cupboard or compartment
permanent air vents are required in the cupboard or
canpartment. one at high Ievef and one at low level
either direct to the outside air or to a room. Both high
and low ieveJair vents must communicate with the
same space
Highlevel 261 cm2 (40 in2, 130 an2 (20 ir?)
Lowlevel
261 cm2 (40 in2) 130 cm2 (20 in2)
2.6 Elerkal Supply
- This appliance must be earthed.
- AII wiring externai to the appliance must conform to
the current B.S. 7671.
- The appliance requires a 240 V - SOHz suppiy.
- Connection of the appliance and any systemcontrols
to the mains suppiy must be through a common
‘rsohtor and must be fused at 3A maximum.
This should preferably be an unswitched shuttered
socket outlet and 3 pin plug to BS 1363.AItemativeiy,
a double pofe koiating switch may be used. provided
ithasaminimumcontactseparationof3mminboth
poles The isolator shouid be ciearfy marked showing
its purpose. preferably positioned close to the
appliance.
-Fuse the supply at 3A.
-The supply cord must be 0.75 mm2 (24 x 0.2 mm)
threecuetoBS65OOTabie16.
2.7
GasSupply
The appliance requires:
2.743 m3/h (96.87 ft31h) gas flow.
The meter and supply pipes should be capable of
delivering this quantity of gas in addition to the
demand from any other appiiances in the house.
The complete Installation must be tested for
soundnessas described in BS 6891.
3
SYSTEMGUIDANCE
3.1
Gened
The low water content appliance boiler inciudes the
expansion vessels. safety overheat thermostat,
temperature and pressure gauges. and safety valve.
The fiow temperature is adjustable and gives a
nominal 82 “C (180” F) on its maximum setting.
Detailed recommendations for water circulation are
given in BS5546. Whiist the boiler provides hot water,
there may be occasions when a cylinder wiil be used,
for instance. if the property has two bathrooms.
Detaiied recommendations of this appiication is given
in section 3.13. Thermostatic control should be used
in the heating circuits and the @rider if one is fitted.
It must be remembered that a combination appliance
has a limited volume of hot water that can be
supplied at any one time for a given temperature.
Indeed in most respects it is equivalent to a muitipoint
water heater and many of the contra&s associated
with muitipoints appiy equally to combination boilers.
The appliance has two separate functions. to provide
heating and hot water on demand. It can have a third
which is to supply hot water high demand through the
use of an indirect cyiiider. where there is more than
one bathroom or if the standard and appointments of
the property, such as basins in ail bedrooms and a
largekitchen indicate a high usageof hot water.
Hot water produced indirect& through a cylinder can
be used to satisfy high simukaneous demand outlets -
bathrooms etc. whilst the benefits of high efficiency in
general& small quantities of hot water, can be fuiiy
utilised in kitchens, cloakrooms and so on.
Separatetime and temperature control over hot water
generated in this way can be achieved by the use
either of two port valves or three port vaives of a flow
shareor priority pattern.
It is also possible, where the occupation of the house
is variable. to provide either for a small or large load.
Thisis bestachievedwith a tail. small diameter cyiinder.
Seesection5 for possiblewiring anangements.
A domestic expansion vessel is fitted to the boiier with
a capacity of 0.16 litres. prior to the secondary heat
exchanger which enables the boiler to be connected
to a cold main water supply containing a non-return
valve or any device containing a non-return valve.
10
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

IF THE MAINS COLD WATER SUPPLY IS IN
EXCESS OF 10 BAR (150 PSI) A PRESSURE
LIMITER MUST BE FITTED TO AVOID EXCESSIVE
PRESSURE BEING APPLIED IO THE BOILER.
When replacing an existing cylinder storage system
with appliance it is essential that all redundant
pipework is removed and dead legseliminated.
In properties where there are multiple dmw-off Points
on different levels consideration shouid be given to
the use of non-return valves in the secondary hot
water system to avoid -active dead legs-. No non-
tetum valve should be less than 1 m (3 A) above the
top of the appliance and ideaiiy shouid be as dose as
possible to the hot water outlet.
3.2 System controfs
The boii is eiec&aiiy cot&oiled and is suitable for
most control schemes currently available in&ding
thermostatic radiator valves and motorised valves.
When using motorised vaives the controis should be
arranged to switch off the boiler when circuits are
satisfied. The boiier requires a minimum ffow rate of
300 L/h (1.1 gai/min) and consequently, if
thermostatic radiator valves are fitted to ali radiators.a
by pass will be necessary. Thii wiii ensure that the
boiler wilI operate correctly when ail TRVsare dosed.
(seefig. 17).
3.3 Pump
The boiler is fitted with a Grundfos iJP.l5/60 pump
head. The graph (6g. 11) indicates the residual head
avafiabie for the system.
flow rate in g.p.m.
flow rate in litres/hour .
Fig. 11
3.4 Expansion vessel
The expansion vessel which is fitted on the front of
the combustion chamber accomodates system water
expansion. The vessel has a capacity of 5.4 litres
(1.19 gals) and is charged to a pressure of 0.65 bar
(9.7 p.s.i.).
THE CONNECTION IN THE CENTRE OF THE
EXPANSION VESSEL IS A CHARGING AND NOT A
VENT POINT.
At the design 5ow temperature and the initial system
pressures quoted the maximum allowable system
volume is 75 iitresif the water voktrne is not known
and cannot be accurately assessed from
manufacturers data the foiiowing volumes may be
used to give a conservative estimate of the system
volume.
Appliance ..........................................4 Iitres (0.8 gals)
Smaii bore pipework ....................0.3 iitres (0.07 gals)
per 0.292 kW
Micro&x-e pipework ..........................7 iitres (1.5 gals)
Steel panei radiators ......................
2.3 litres (0.5 gals)
per 0.292 kW (1000 Btti) of system output
Hot water cyiinder ..,..................... 2 litres (0.44 gais)
If the volume exceeds 75 litres an additional vessel
wiii be required fitted in the tlow from the appliances.
Refer to BS 7074 Pt. 1or BS 5449 for detaiis of siring.
3.5 Mains water connection
There shall be no permanent connection to the
Iiratng system Pipework for filling or replenishing
without tt;e approval of the Local Water Authority (see
Byelaw No.14 and figs. 12 and 13).
3.6 Filling point (see B-S.5449)
FUling and recharging can be done :
1) Through a temporary hose connection to mains
water.
A stop-valve should be fitted to the service main outlet
and a double check vaive assembly and stop-vaive
should be fitted to the system side of the temporary
hose (see tig. 12).
2) A cistern used for no other purpose connected to
the mains water.
The static head provided by the cistern myzt be
sufficient to satisfy the designed initial system
pressure. The supply pipe from the cistern should
include the double check valve assembly and
stopcock (see fig. 13).
3.7 Make up system
Provision must be made for repia&-g water lost &om
the system indicated by a reduction in pressure
shown on the pressure gauge. Recharge through the
tilling point (see section 3.6).
3.8 Pfpework
Pipework can be of copper or suitable plastic. smaif
bore or microbore with capillary or COmpreSSiOn
jointing to a high standard. leak sealant must not be
used in the system.
3.9 Domestic expansion vessel
The expansion vesseiwhich is fitted on the cold water
supply to the secondary heat exchanger accomodates
domestic hot water expansion. The vessel has a
capacity of 0.16 litm (0.035 gals) and is charged to a
pressure of 2 bars (30 p.s.i.); it has a maximum
working pressure of 10 bars with an allowable
pressure peak of 14 bars.
11
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

Air inlet
valve
Double check
Hose
valve - .
Test co&
(a) Non-automatic filling and make-up. Temporary hose filling loop avaible, Pt.No.CHL112
Fig.12 .
Heating circuit /
retumWT valve
Test cock
satisfy the
designed initial
system pressure
Fig. 13
(b) Automatic filling and make-up.
3.9.1
3.9.2
3.10
3.11
Bolter replacement (retrofit)
Inanddsystemwheretheboikrisbehgrepked,
we recommend the use of a strainer, fitted with a
drain tap on the heating return. designed to retain
scaleprtides and other solid debris It is good practice
to use a chemicai cleaner with a floctuating agent.
used as reaamrnended by the deanser manufacturer,
to clean the syst+xn before the old boiler is removed.
(seeBS7593).
VaIvesandjoints should be carefullycheckedfor leaks
and the appmpdate action should be taken either as a
repair or repiacement. The old open system has
probably only been subjeaed to a pressureof 0.4 bar
or leas. When you change to a sealed system where
thechargepressurewillbe1.Obarandtherunning
pressure exceeding 1.5 bar. consideration should be
given to the replacement of radiator valves with a
pattern capable of seaiing at the higher pressures.
Cylinder.
Where a domestic hd water cylinder is used with the
appliance it MUST be of the indire~ and high recovery
type to BS 1566 Pt 1 Single feed cylinders are not
suitable for use with this appliance. Flow and retum
pipework to the +nder should be in 22 mm pipe.
Inhibitor and water conditioners
(see Bs 7593)
Chaffoteaux et Maury generally recommend the use
of inhiirxs in systems using the appliance boiler.
3.12
The following are the appliance manufacturer’s
recommendations :
I) Use only a British Gasor similar approved inhibitor.
These manufacturers can assistwith the selection.
GraceDearbom Ltd - Wlclnes- CheshireWA8 8 UD
Tel:[phone].
Femox Manufacturing Company Limited Britannica
Works, Clavedng. EssexCBII 4QZ
Tel: [phone].
2) Use only the quantities specitied by the inhibitor
manufacturer.
3) CIeanse the system as required by the inhibitor
manufacturer.
4) Add inhibitor only after flushing when finally re-
filhg the system.
5) In-line water conditioners both of chemical and
magnetictype aresuitableforusewith the appliance.
Add-on devices
It is important that no external control device; e.g..
economisers be directly fitted to this appliance unless
covered by these installation instructions or agreed
with the manufacturer in writing. Any direct
connection of a control device not approved by the
manufacturer could make the guarantee void and also
inkinge the GasSafety(installation & Use) Regulations.
12
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

STERLINGPP Heating
& stored hot
water - spring return
3.13 Heating and hot water systems
Figs. 14. 15. 16 and 17 indicate various layouts for
the production of hot water. It is recommended that
only a high recovery indirect cylinder is used and
circumstances may from time to time dictate that a
special saturated heat exchanger in an indirect
cylinder may be desirable.
When replacing an exisiting cylinder storage system
with an instantaneous type system it is essential that
all redundant pipework is removed and dead legs
eliminated.
Heating & stored hot
STERLINGPP water using flow share
I relay required
The consideration of heating systems using
thermostatic v6alvesshould ensure that the minimum
flow rate thrcr:::h the appliance is maintained at all
times and in ?X znnection the remote by-pass is
preferred (see fig. 17).
1Fig. 16
STERLING PP
1
Remote by-pass
remote by pass
with US valve
instant
hot water
13
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388

3.14 Shower Application
The appfianoz can be used to supply hot water to separateshower draw-off. It m not be used to suppty more than
cne shower mixing valve.
The recommended pipework arrangement for a shower is shown below and the hot supply to the mixing vatve should
be the tirst draw off.
HOT COLDWATER
COLD
I
Fig. 17a
It is important to select a compatible shower for the appliance. The following manufacturers can assist with the
seiection
New Team Ltd
Brunell Road
Earlstree Industrial Estate
@bY
Nolthants NNl7 2LF
Meynell Valves Ltd
Shaw Road
Bushbury
Wohrerhampton
West Midlands WV1 0 9LB
Tel.No.56 32 40 Tei.No.0902-28621
Aqualisa Products Ltd
Hortons Way
London Road
Westerham
Kent TN1 6 1BT
Barking Grohe
1 River Road
Barking
Essex 1Gll OHD
Tei.No.0959-63240 Tel.No.081-594-8898
Do not use the appliance with push on hand showers that fit over hot and cold taps.
14
Unit 3A, Thornton Road Ind. Estate Off Hockney Road Bradford, BD8 9HQ
01274 488 388