Chaffoteaux & Maury Sterling SB 60 User guide

s Sterling System Boiler
Room Sealed Fanned Balanced Flue
Sealed System Boiler
GAS SAFETY (INSTALLATION AND USE1REGULJYTIONS.
It is the law that all gas appliances are installed by a competant person
in accordance with the above regulations
(For use on natural gas only. G20)
Installation and Servicing Instructions
(leavetheseinstructionswiththe user)
Looktng Good.Heathg Better

HealthandSafetyInformation
Paae
1
1. INTRODUCTION
1.
1.1.
1.2.
13.
1.4.
1.4.1.
1.4.2.
1.43.
1.4.4.
1.5.
1.6.
1.6.1.
1.6.2.
1.6.3.
1.6.4.
1.6.5.
1.6.6.
1.6.7.
GeneralDescription,SpecialFeatures,Guarantee
DimensionsFig. 1
TechnicalData
Cl~CeS
wall Thickness
RearFlueOutletFig.2
SideFlueOutletFig.3,Fig. 3a,Fig.3b
OtherFlue Arrangements,HorizontalFig. 3c
Vertical FlueArrangements,Fig.3d.Fig.3e,Fig.3f Fig. 3g
Descriptionof ComponentsandLocationFig.4
Descriptionof Operation
CentralHeatingFig.5
Hot WaterFig. 6
Gas(alsosee2.7)
FunctionalFlow DiagramFig. 7
SafetyControls
FunctionalFlow Wing DiagramFig.8
illustrated Wiring DiagramFig. 9
2. INSTALLATION REQUIREMENTS
2.1. General
22. Location
23. WaterCirculation System
2.4. Siting theFlueTerminalFig. 10
25. Air SupPlY
2.6. Electrical Supply
2.7. GasSupply
3. SYSTEM GUIDANCE
3.1. (Z&mrai
32 SystemControls
3.3. pumpFig. 11
3.4. ExpansionVessel
3.5. MainsWaterConnection
3.6. Filling andRechargingFig. 12.Fig. 13@age12)
3.7. Makeup System
3.8. Pipework
3.9. DomesticExpansionVessel
39.1. Boiler Replacement
392. Existing systems
3.10 Cyhnder
3.11 Inhibitors andWaterConditioners
3.12 Add onDevices
3.13
Heating andH&Water SystemsFig. 14.Fig. 15,Fig. 16.fig. 17
3.14 ShowerApplication Fig. 1%
2
2
3
3
3
4
4
4
5
6
7
7
7
8
8
8
9
10
11
11
11
11
12
12
12
12
13
13
13
13
13
13
13
13
14
14
14
14
14
15
16
(9

cclLm2m (con0
4. INSTALLING THE BOILER
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.
4.14.
GeneralInformation
PositioningtheBoiler Fig. 18
RearOutletFlueFig. 19
SideOutletFIueFig. 20
Jig PlateFig. 21
GasandWaterConnectionsFig. 22
water COMtXtiOIkS
GasConnection
Fitting theBoilerFig. 23
Fitting theSafetyValveFig. 24
Fitting theFlue(upto 700mm long)Fig. 25
Fitting theFlue(over700mmlong)
ConnectionthePressureSwitchFig. 26
Electrical &MeCtiOllS fig. l?7
VerticalFlueFigs.28,28a, & Fig. 29
5. EXTERNAL CONTROLS
5.1. ProgrammingandZoneValvesFig. 30
52. Honeywell& Sat&well ControlledZonesFig. 31
53. FrostthermostatFig. 32
5.4. RoomThermostatFig. 32a
17
17
17
18
18
18
18
18
19
19
19
20
20
20
21
22
22
22
22

To comply with the Control of SubstancesHarmful to Health Regulation .1988
provide information on thefollowing substancethatis containedin this appliance.
CombustionChamberLining
Material Alumino SiliconeFibre
we are required to
During servicing, keep the dust generation to a minimum and avoid
inhaling any dust andcontactwith the skin and eyes.Normal handling
and usewill not presentany discomfort, although somepeople with a
history of skin complaintsmaybesusceptibleto irritation.
When disposing of the lining ensure that it is securely wrapped and
washhandsaftercontact.
1

L INTRODUCIIOiN
The STERLINGSB is a waft mounted, low water content
fanned balanced flue appliance suitable for central heating
and hot water via a fast recovery indirect cylinder. The
maximum output is 17.5 kW (60,ooO Btti) and 23.3 kW
WWOO Btwh).
The boiler is designed for sealed systems only and inciuded
in the appliance are the expansion vessel, circulating pump.
optional 3 ports mid position valve, a pressure gauge,
Safetywtlve. electrical amnection and plug by-pass.
1) The standard 5ue assembv supplied with the boiler is
100 mm (4 ins) diameter pipe, it can be directed to the rear
or to the left or right and, can be extented to a maximum
length of 3 meters, or 1.6 meters horizontally using the
available 90” bend (see sections 1.4.1, 1.4.2 and 1.4.3.
figures 2.3.3a. 3b. 3~).
2) Vertical ffue option available is 12s mm (5 ins) diameter
pipe which can extend up to a maximum of 9.5 meters
straight. 8 meters with 2 x 45” bends. or 6 meten with 2 x
90” bends (seesection 1. 4.4).
Special futures fndud- -
- Fuky range rated between 10 to 23 kW for SB 80 and 9
to 17.5 kW for SB 60.
- High effidency.
- Fixing piate.
- Adjustable ffow temperature central between a nominal
60” Cand 82” C.
- High limit tllermostat.
- Built in by-pass.
- Integral pump.
- expansion vessel.
GUARANTEE
The manufacturers guarantee on this appkanceis for 12 months from the date of purchase. The guarantee is nulle and void.
if the appliance is not installed in accordancewith the recommendations made herein.
1.1 DIiENSIONS
Fig. 1 .
R’-
k
SIDE OUTLET
A
820.5
B
391.0
C
365.0
D
100.0
E
169.5
F
654.5
G
100.0
H
50.0
J
260.0
K
972.5
L
13.0
M
61 .O
N
30.0
P
152.0
R
112.0
mm
in
32.3
15.4
14.4
4.c
6.7
25-
4
ii;
10.2
38.3
0.5
2.4
1.2
6.0
4.4
2
:

i
1.2 TECHNICALDATA
Cued hutiag
Maximum input.. ........................
Maximum output.. ......................
Gasmte (maximum) ...................
Burner pressure.............. ..‘........ ..
Minimum input.. .........................
Minimum output ........................
Gasrate (minimum) ...................
Bunter pressure..........................
Minimum Bow rate .....................
lbfaimurn pressure.....................
k the muimuzu preasra loss 04
Temperature of the products of
combustion : ..............................
TheCOcontent of the dry &eeair
productsof combustion : ............
STBRLINGSB80 I STERLING SB 60
1
26.1 kW
23.4 kW
2.63m3/h
9mbar
12kw
1okW
1.Om?h
1.3mbar
5oom
2.5 bar
1
89058 Btulh 19.80 kW 67561 Btulh
79845 Btufh 17.75 kW 60566 Btufh
92.98 ft3/h 2 m3/h 70.71
fl3h-i
3.6 in wg 7.2mbar i 2.9
in wg
40946 Btu/h 11.10 k 37875 Btti
34122 Btwh 9kW 30709 Btw-h
35.31 fwh 1.Om3/h 35.31
A3ll-l
0.5 in wg 1.7 mbar 0.6 in wg
1.8gaYmin 3OOvh 1.1 gavrnin
36.5 psi 2.s bar 36.5 psi
It!flue I
0.0136%
Natud gas
injectors number 14 12
Manifold injectors ....._.......l........ 1.28 mm 0.05 in 1.28 mm 0.05 in
Manifold restrictors .._.._._....__....... 4.7 mm 0.18 in 3.8 mm 0.15 in
COMUtiOllS
GaS
.............................................................. 22 mm copper
Heating a0w (2)........................................... 22 mm copper
Heating return.............................................. 22 mm copper
Electricalsuppiy 230 V - 50 Hz. fused at 3h
(on command box)
Electricalconsumption .............................-... 195 watts
Intemaliyfused.twoat2A(BS4265)
Weight.....__........._...._._.....__._................_._.....42 kg 92.4 lb
Watercapacity ...__...__....._._...........................4 litres 7 pints
Ignftion - HONEYWELL
Ignition electrode - SAPCO,ARC0
IgEM pm3he- SAPCO.AFCO
Bokr lhnlt thermostat - ELhlWOOD/ TOKOSWITCH(85X)
Bof!uregufaffoll thamostat - Mrr
safety amrhut thcrmo8tat ( E7,hMaD- - (105°C)
(manual reset)
Gasvahre-HONEYWEU/SIT
Fanmotor - SRI.
Prusom switch - DUNGS/ TRIDELTA/ HONEYWEEL.
Pump head - GRUNDFOSUP 15E.O
-~fnftfrIchupcpiamrr - 0.65 bar (9.6 psi)
IbmesticqansionvuseIiuItialchagc~-2bar(3Opsi)
1.3
1.4
MINIMUM CLEASWCES AROUND BOILER
Top above air duct .......... 5omm (2in)
Bottom beIow case.......... 150 mm (6 in)
skies .*............................. 1OOmm (4in)
Front ............................... 600mm (24 in)
WAUIHICKNESSBS
The standard ftue assembly can accomodate the folkwing thicknesses.
Rear:from40mrnto576mm
Siie:~om40rnmto392mm
(this allows for a minimum clearanceof 100mm between the appliance and the side wali. As this dimension inaeases.
so the maximum sidewall thicknessavailabledecreases).
&fern&n flue assemblies are availableto accomodatewall thicknesses of :
Rear: ~om577mmto2876mm
Side : from 393 mm to 2692 nun
IMPORTANT NOTE : The extension ducts supplied, up to a maximum of 3, will in fact pennit a greater length than
indicated to be covered. The ducts MUSTbe cut so that therrkdrnurn length kom the oentreline of the fiue turret
to the
outermost point of the air duct DOESNOT MCEED 3 metres hodzontai. Greaterlength must not be used.
Seesections 1.41 1.42. 1.4.3.
3
i

1.4.1
1.4.2
I
1
REARFLUE OUTLET HORIZONTAL
To cut ffae uaembfy to kngrh
- Measure walI thickness 0.
- Add 74 mm. this wiii give rquired length (L).
- Mark plastic air duct for Iength (L) and cut off
surplus (kern plain end).
N.B. If extension sections are used ensure these are
- firmly pushed together. see figs. 3b and 3c and a faii of 5
mm per metre length should be provided (see section
- Cut off same amount from ak.&niurn flue duct
Flueextensionaccessory
Part No.62823.00
REAROUWETASSEYBLY
:ig. 2
SIDE FLUE OUTLET HORIZONIZL
external internal
To cut flue urrmbfy to [email protected]
- Measure from external wall face to centre fine of
STERLINGSB and substract 37 mm (this will gii
required length Q.
- Cutoff surpIus from plastic air duct (pIaii end).
N.B. If extension sections are used ensure theseare firmly
pushedtogether.seeEgs.3band3candat%iIof5mm
- per metre Iength should be provided (see section
0’ - Cut off same amount fiorn aluminium flue duct (plain
- Fit the rubber sleeve between the flue turret and the flue
Flueextensionaacessq
Pm No. 62823.00
RASTICAIRDUCT
ALUMINIUM FLUEDUCT
OlHERFLUEARRBNGEMENlS
BORIZONIAL
1. Distance from internal comer 300 mm without kit.
107 mm with kit No 76216 (GCNo 264 833).
2. Distance below balconies or eaves 200 mm
without kit. 107 mm with kit No 76216 (GCNo
264 833).
3. Appliance is normally supplied packed with stan-
dard 650 mm straight 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 flue using part No
65572 (GCNo 264 835). In this case the Iengrh
Ll + L2 should not exceed 1.6 metres horiron-
Fig.3c . W
4

1.4.4 VERIICALFLUEARR&NGEMENTS
Fii.3d
Fig.3f
,
m Fig. 3 g
P
a) Strdg&t ffae (fig. 3 d)
1) Adaptor.
2) F~ensions (9.5 m maximum).
3) Roof Bashing.
4) Terminal
6) Reducer.
b) Fke wkb two 4S” bends (f& 3 c)
1) Adaptor.
2) kknslons (8 m maximum).
3) Roof tlashing.
4) Term&L
5) 45” bend.
6) Reducer.
c) Flue wkh four 4f” beads (ffg. 3 I and 3 g)
1) Adaptor.
2)Extensions(6mmaximum)fig.3fand3ginclu-
dinghorizontal(2m~um)fig.3t
3) Roof flashing.
4) TemGnaL
5) 45” bends (x 4 Wum)f&3fand3g.
6) Reducer.
With the aceptlom of (3) roof fbhfag and (4) taml-
aal, all otha fftthgs arc designed for fatand fnrtal-
kttotl o*.
N.B. In these two anangements figs. 3 f and 3 g. the
total length of straight extensions ~~l~dsfnot exceed 6
metrewitha maximumof4x45”bendsor2x90°
bends.
Horizontal mn must not exceed 2 meters.
Important : When the vatkal he exceeds 5 metem,
pzwidonwillhavetobemadctodnfatheomdea-
rrte.
5

1.5 DESCRIFTION.OF COMPONENTS AND LOCATION
Fig. 4
The appliance is mounted in a steel case which has a white
epoxy resin paint tinish.
1. Chassis:
The chassis is a rigid plated mild steel pressing on which all
components are mounted.
2. Flue hood :
Is an aluminium alloy casting onto which the fan is mounted.
3. bmhustion chamha :
This is as.sembIedkom a number of components mounted
onto the chassis.The Gent panel is simply removed for seti-
cing complete with the expansion vessel, a hook is fitted
below the appliance to accept and retain the panel during
sticing.
4. Expa&on vessel : (not illustrated)
The expansion vessel has a capacity of 5.4 litres (1.19 gal)
and is sized for a non-r& system water content where the
Ioad is equiAent to the maximum output of the boiier. The
chargepressure is 0.65 bar.
5. Flame supavhbn ddce (not illustrated).
6. Mrdtigas bmna comprising : stainless steel blades (14)
and a manifoid with injectors (14).
7. Gas section including main soleno’fdvalve and addditionai
security soleno’fdvalve.
8. Three ports mid positbnee (Opho~O
9. Electrkfal box aantahhg :
Mains connection
Fuses
ControI box
Connections for external controk
Connections for fan and pressure switch
Connections for pump
Connections for optional three ports mid position
valve and pmgrarnmes
10. Connection for gasvalve.
11. Grundfos pump motor 15150
12. Ak separator and vent dire* connected to the pump
inleL
13. Regafation screw to adjust output to heating of boiler-
14. Heating body com~g :
Copper tinned ‘tube heat exchanger protected with silicone
resin paint. Combustion chamber in aluminium coated steel.
Combustion chamber hing - ceramic fibre pads.
15. Hig& Emit themostat (manual reset).
16. flow for hot water cylinder (optional).
16. GasseAee tap (no4illustrated).
21. Lock out hadlator light.
22. Main ON/OFF switch.
25. Thermostat to regulate flow tempemture.
27. Air pressure switch.
28, Fuse.
29. Pressure gauge.
30. Data badge posMon (on sealcxfaver).

1.6 DESCRIPIIONOFOPERAIION
The STERLING System Boiler provides centrai heating
and hot water in conjunction with a fast recovery indirea
cylinder. The selector switch can be set to hot water only
when using the 3 way optionaI vaIve or to heating and
hot water. If the valve is not fitted when the sutch must
to set to hot water ad-he&.
1.6.1 cENTRALHEKIING~seeiig. 5)
When external controls demand heat the boiler
thermostat energises the central box and the fan
operates to purge the combustion ciamber.
High tension voltage is then applied to the ignition
electrode and a stream of sparks pass from the ekctrode
to the bumer assembly. The gas vaIve then opens and
allows l/3 rd of the maximum gasto pass to the burner
for ignition. Once the flame has been proven by the
ionisation circuit, the gas rate increases to the adjusted
set rate.
At the same time the pump circuIateswater around the
heating system, which retums to the boikr via an air
reparator. an air purger, and an isolating vaIve
contraining a filter. It then passes through the heat
exchanger where it is heated, and on to the radiator
circuasvia the 3 way v&e if &ted.
There is a manually adjusted by-pass connected
between the flow and retum.
Temperature central is by means of a thermostat,
between 50°C and 82°C
Expansion Provision is avaiiable via an expansion vesseI
connected to the return valve.
When The BOW temperature nEh%es the set level. fhe boiler
thermostat de energises the control box ad the burner is
extinguished and the circulations Ponys contunues to
operate. Of extemed controls are satisfied then the burner is
extinguished ad the ciradating pump stops.
1.6.2 HOTWAIER~ optiona1seetig.6)
When extend contds dknande heat the ix&r thermostat
energises the controI box and the fan operates to purge the
combustion clamber. High tension voltage is then appiied to
the ignitim electrode and a stream of sparks pass fan the
ekctrode to the burner assembIy. The gasvaIve then opens
and aIIows l/3 rd of the maximum to pass to the burner for
ignition. Once the fIarne has been proven by the ionisation
circuit, the gas rate increases to the adjusted set rate. At the
same time the pump circuIates waters, around the primary
circuit of the sekcted hot water cylinder, which returns to
the boiler via an air separator, an air purger and an isolating
valve contmining a 5Iter.
It then passes through the hect exchangeur where it is
heated and on to the primary circuit of the se&ted hot
water cyIinder. via the 3 way vake. Temperature control is
by means of a thermostat between 50°C and 82°C but an
aditional cyIinder thermostat is recomended.
Expansion provision is avaiIable via an expansion vessel
connected to the return w&e.
When the ffow tempetature reaches the set Ievef the boiler
thermostat de energises the control box and the burner is
extinguished and the circukting pump continues to operate.
If the extemai controls are satisfied then the burner is ext
inguished and the circuIating pump stops.
Central Heating
Fig. 5
Hot water
I
Fig. 6

1.6.3 GAS (seefigs.5
and 6)
1.6.4
circuit. If the main burner is not established after 5
seconds then the boiter tbils safe to lockout and has to be
WhenUlegassenriceistrtmedwahasaew~etothe
on position gasis adrniied to the gassection. reset
manuaEy by operating the main ON / OFFswitch.
When there is a demand for heating or hot water, the gas
Mhre is energised and it aIIows gas to pass to the burner.
Simultaneously the high tension voltage produces a
stream of sparks between the two ignition electrode
which ignites the gas, after few second the gas rate
increasesto the adjustested rate.
The flame supervision is controlled by an ionisation
FUNCTIONAL DIAGRAM
SSEC LuxcutllhE
MANlMLREs3tw
PowR.swTTa4
(optional) I 3portsv&f0
8
1

ELECTRICAL FUNCTION DLKGRAMwith pack
programmer
I I It
d!
main on/+ 4-k
I+
-..--..-..
L-
/
\/
I
- I I I-1
3 mid
position
control
- box
1.6.6 ELECTRICAL FUNmON DIAGRAM with-t pack
main on/off 8wkh
L
47 I
mom stat
0’----
St- &T 1
N
E___1,,
I gasvalvas >
P-m
8witdl
ti
i
control
’ box
9

1.6.7 XLLUSIRAIEDWIRINGDIAGRAM
Flame supervision
Safety overheat
Boiler limit stat thermostat
(automatic RESFF) (manual RESET)
E
Bk-
TO
oktrIal
. -
N
Ignition
electrodes
Lock out
indicator
light
Pressure switch
rw
Gas valves
Pump Er Boiler regulation stat
IL-
B = blue
Bk = black
Br = brown
Ge= green
MP mauve
Or P orange
R = red
v = violet
W= white
Y = yellow

2 INSTALLRTION REQUIREMENTS
2.1
2.2
GENERAL
The installation of the boiier must be in accordance
with Gas Safety (Installation and Use) Regulations.
Building Regulations and current of the local Water
undertaking. It should be in accordancealso with the
current BS Codes of Practice and the British Gas
Specifications for Domestic Wet Central Heating
Systems and any rekvant requirements of the local
Gas Region and Locai Authority Building Standards
(Scotland) Regulations and the Safety document 635
the Electrkity atWork Regulation.
Detailed re
commendations are stated in the following
British Standard Codes of kacticez
B.S. 6891.B.S. 6798, B.S. 5448 : I and 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.
Note : Gas Safety InstaUation 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 correctly could lead to
prosecution. It is in your own interest and that of
safety to ensure compliance with the law.
LOCATION
The boii 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 adequate spacefor servicing
and air circulation around the boiler. The surface on
which the boiler is mounted must be of non
combustible material
The bcder 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 utilisii mains electricity in a
room or internaSspacecontaining a bath or shower.
Where the installation of the boiler wili be in an
unusual location special procedures may be necessary
and BS 5546 gives detailed guidanceon this aspect.
A compartment used to enclose the boiir must be
designed and constructed spe&caRy for this purpose.
An existing cupboard or compartment may be used
provided that it is mod&d for the purpose
Details of essential features of cupboardkompart-
ment ciesiin are given in BS 6798.
2.3 WATERCIRCULATION SYSTEM
The STERLINGSB is suitable for SEALEDSmS
ONLY and should be installed in aaordance with the
relevant recommendations given in BS 6798, BS
5449:1 (for the smallbore or/and microbore systems)
and the British Gas Specitiations for Central Heating
systems.
2.4 SITING THE FLUE TERMINAL
Refer to section 1.4 for details of wall thicknesses
which can be covered.
Detailed re
commendations for ffueing are given in BS
5440 Pt 1. The following notes are intended to give
genefai guidance.
The bder must be instaUedso that the ffueterminal is
exposed to external air. The boiler must NOT be
installed so that the terminal discharges into another
room or space e.g. outhouse 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 openings are specified
below (tig. 10).
Horizontal Flae
Terminal podtlonr Mhlclrorances
A - Lkedy below an opening, windowsetc
or adjacentto an opening ..................._..300 mm
E - z2f zu soil pipes or drain pipes... 75’mm
- ........‘-....‘....-................‘-.’-”
200mm*
D - Below balconies or car port roof ........__.-200 mm*
E - From a vertical drain pipe or soil pipe.... 75 mm
F - From an internal or extemal comer _.._....380 mm*
C - Above ground roof or balcony level_..._..300 mm
H - From a stice 4dng the terminal....._.._600 mm
J-Fromanopeninginthecarport
(e.g. door or window) into dwellI@ ........1200 mm
K - Vertically fom a terminal on the same
...............................___........._..-.....-...
1500mm
L-Horizontallykomaterminalonthe
samewall ............_.....__......-...............-...
3oomm
l (107mm)minhxnckamazus’~
kitNo.76216.oO(c.C264833~see~14~.~.~~
Vextical Flae
nrdnd posMons Mincf~cu
M - Above intersection with Roof ........._...._.150 mm
1Fig.10

BUILDING REGUIATIONSexcerpt.
&provaf document-j Part B 1.4 (C)(D).
c) Protect with a terminal guard iitted centrally over
the terminal if it could come in contact with people
near the building or Ix subjected to damage.
D) Designed so as to prevent the entry ot any matter
which might restrict the flue.
(A terminal guard GC. No 381782 is available from).
Quinnel Banet & Quinnel Wiiorks
Old Kent Road
London SE15 INL Tel [phone]
The air inleVoutlet duct and the terminaI of the
appliance must not be closer than 25 mm (1 in) to
any combustible material. Detailed recommendations
on the protection of annbustiable material are given
inBS544OPtl.
IMPORTANT NOTICE : TTMBERFRAMED HOUSES
~THEAPPLIANCEISTOBEFllTEDINAAER
FRAMED BUILDING IT SHOULD BE FITTED IN
ACCORDANCE WITH THE BRITISH GAS
F’UBLKFJION - “GUIDE FOR GASINSTALIAl-lONS IN
TIMBER FRAMED HOUSING’ reference DM2. IF IN
DOUBT, ADVICE MUST BE SOUGHT FROM THE
LOCALREGIONOF BRITISH GASORCOR.G.1.
2.5
AIR SUPPLY
The room in which the boiler is instaIled does not
require a purpose provided air vent
Ifthe boiler is installed in a cupboard or compartment
pemxment air vents are required in the cupboard or
compartment. one at high IeveI and one at low leveI
eitherdirecttotheout.sicIeairortoaroom.BothhIgh
and low Ievel air vent 5
same space
must cornmu
ni kate with the
I
Podtioaofwab
240 an2
240 an2
180 an2
18QUll2
Akdhctfmm
oatddr
120 cm2
120a-n2
9oan2
9oan2
2.6
EIectrkaI StfppIy
-This appliance must beearthed.
- All Wiring external to the appIiance must conform to
the cummt B.S. 7671.
-TheSTERLJNGSBrequiresa230V-50HzsuppIy..
- Connection of the appliance and any system controls
to the mains supply must be through a common
isolator and must be fused at 3Amaximum.
Thii should preferabiy be an unswitched shuttered
socket outlet and 3 pin plug to BS 1363. Altematively.
a double pole isdating switch may be used, provided
ithasa minimumcontactsepalationof3mminboth
poles. The isolator should be cIearIymarked 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)
three are to BS 6500 Table 16.
2.7
3
3.1
GASSUPPLY
The STERLINGSB requires:
The meter and suppty pipes should be capable of
delivering this quantity of gas in addition to the
demand from any other appliances in the house
The complete Installation must be tested for
soundness z-described in BS 6891.
SYSTEM GUIDANCE
GENERAL
The Iow water content SIERUNG SB boiler indudes
an expansion vessel, safety overheat thermostat,
safetyWe. pressure
The ffow temperature is adjustable and gives a
nomInaI 82 “C (180” F) on its maximum setting.
Detailed recommendations for water circulation are
given in BS 5546. When the boiler provide hot water,
a fast recovery cylinder will be used, detailed
recommendations of this application are given in
sections. A cylinder thermostat is recommanded.
Separatetime and temperature control over hot water
generated in this way CM be achieved by the use of
the optional three way ties in a conjunction with a
cylinder thermostat and programmer.
12

3.2
3.3
3.4
When replacing an existing cylinder storage system
with STBIUNG SB it is essentiaI that all redundant
pipuwork is removed and dead legseliminated.
In properties where there are multiple drawoff Points
on different levels consideration should be given to
the use of non-return -Ives in the secondary hot
water system to avoid active dead lelgs. No non-
return valve should be less than 1 m (3 It) above the
top of the appliance and IdeaIly should be as dose as
possible to the hot water outlet.
SYSTEMCONTROLS
The boiler is electricany controlIed and is suitable for
most control schemes currently available including
thetmostatic radiator valves and motorised valves.
The boiler is fitted with a Grundfos UP.15/50 pump
head. The graph (IQ. 11) indicates the residual head
avaiIablefor the system.
When using motorised valves the controIs should be
arranged to switch off the boiler when circuits are
Fig. 11
satIsfieId.The boiler requires a minimum flow rate of
500 L/h (2.2 gaI/min) and consequently, if
thermostatic tad&r valves are &ted to all radiators,
ad&sment must be made to the internal by-pass to
ensure that the boiler operates correctly (seeIig. 17).
P-P
EXPANSION VESSEL
The expansion vessel which is fitted on the front of
the combustion chamber accomodates system water
Flowrataing.p.m.
Plow rat. h Iitrwltour
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&i.).
THE CONNECTION IN THE CENTRE OF THE
EXPANSION VESSEL IS A CHAECING AND NOT A
VENT FOINT.
At the design flow temperature and the initial system
pressures quoted the maximum allowable system
vdume is 75 litres. The water volume is not known
and cannot be accurately assessed from
manufacturers data the foIlowing volumes may be
3.5
MAINS WATER CONNECTION
3.6
There shall be no permanent connection to the
Heating System Pipework for 6Iliig or replenishing
without the approval of the Local Water Authority (see
Byelaw No.14 and figs. 12 and 13).
FILLING POINT
Fii and rechargmgcan be done :
1) Through a temporary hose connection to mains
water.
A stop-valve should be fitted to the servicemain outlet
and a double check valve assembiy and stop-valve
should be Pted to the system side of the temporary
hose (seefig. 12).
2) A cistern used for no other purpose co~ected
to
the mains water. The static head provided by the
dstem m be suf6dent to satisfy the designed initial
system pressure. The suppfy pipe from the cistern
should include the double check vaIve assembIy and
stopad (see fig. 13).
3.7 MAKEUPSYSTEM
Provision must be made for replacing water lost from
the system indicated by a reduction in pressure
shown on the pressure gauge. Recharge through the
6IIingpoint (see section 3.6).
3.8 PIPEWORK
used to give a conservative estimate of the system
volume.
%kr ..............__......-....................-.... 4 litres (0.8 gals)
SmaIl bore pipework ......-.......... 0.3 litres (0.07 g&i)
per0.292 kW
Mibore pipewo* ..........................7 I&es (1.5 gals)
steel panel radiators ._......_............. 2.3 litres (0.5 gals)
per 0.292 kW (1000 Btuih) of system output
Hot water cylinder .......-...--........... 2 IitIes (0.44 gals)
If the volume exceeds 75 litres an additional vessel
wilI be required t&d in the flow Eromthe appliances.
Referto BS 7074 Pt. 1 or BS 5449 for details of siziig.
Pipework can be of copper or’suitable plastic, smaIl
bore or microbore with capillary or compression
jointing to a high standard. Leak seaIant must not be
used in the system.
13

Air inlet
valve
Double check .
valve assembly Hose
valve i-
Test cock Temoorarv
(a) Non-automatic filling and make-up. Temporary hose tilling loop avaible, Pt.No.CHL112
Overflow .__......
-I- I
..i_.i.
...i
L...........
........_......
,:.:.:.:.:.:.:.
Double check
Hea;:;: ~ valE?blY ~~~
Test cock
-_
I
Fg. 13 (b) Automatic filling and make-up.
J
%o be located
above highest
point in the
system and
satisfy the
designed initial
system pressure
3.9.1 BoUer replacemAt (retrofit)
Inanddsystemwheretheboilerisbeingreplaced.
we recommend the use of a strainer. fitted with a
drain tap on the heating return. designed to retain
scale partides and other solid debris. It is good
practice to use a chemical deaner with a fIoctuating
agent, used as recommended by the cleanser
manufacturer, to clean the system before the old
boiler is removed. (seeBS 7593).
3.9.2 Existing llystems
Valves and joints should be carefully checked for leaks
and the appropriate a&on should be taken either as a
repair or replacement. The old open system has
probabIy onIy been subjected to a pressure of 0.4 bar
or less. When you clmnge to a sealed system where
thechargepressurewiIIbe1.Obarandtherunning
pressure exuxding 1.5 bar. consideration should be
given to the repIacement of radiator valves with a
pattern capable of s&g at the higher pressures.
3.10 Cylinder
Whexe a domestic hot water cylinder is used with the
STERLING SB it must be of the indirect and fast
recovery type to BS 1566 Pt 1 Single feed cylinders
are not suitable for use with this appliance. 3%~ and
return pipewak to the cyIinder should be in 22 mm
Pipe-
3.11 Inhibltom and water conditioners
(see BS7593) .
Chaffoteaux et Maury generally recommend the use
3.12
of inhibitors In systems using the STRRLTNGSBboiler.
The following are the appliance manufacturer’s
reoommetxkttions :
I) Use only a British Gasor similar approved inhibitor.
These manufacturers can assistwith the selection.
Grace-rn Ltd. Wiies. CheshireWA8 8 UD
Telz051424 5351.
Femox Manufacturing Company Limited. Britannica
Waks. Clavering. EssexCBI! 4QZ
Tel: [phone].
2) Use only the quantities specified by the inhibitor
manufacturer.
3) Cleanse the system as required by the inhibitor
manufacturer.
4) Add inhibitor only after flushing when tinally re-
fining the system.
Add-on devtces
It is important that no external control devices e.g.
economisers be directly fitted to this appliance uniess
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.
14
:

I Heating 8 stored ho
STERLING S8
water - spring return
I L f
I valves onlv I
STE Heating & stored hot
iRLlNGSB water using flow share
I 1 relay required
I
FIg.YS
I STERLINGSBSTERLINGSB Remote by-passRemote by-pass
built in by passbuilt in by pass
remote by pass remote by pass
with us velvewith us velve
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 fast recovery indirect cylinder is used and
circumstances may from time to time dictate that a
special s&waled heat exchanger in an indirect
cyiinder may be desirable.
When using thermostatic radiator valves, the
minimum flow rate through the boiler must be
mainkned at aII times. The build in by-pass is set in
the closed position during manufacture and may
require ajustment. Atecnativ~ a remo!e by passmay
be instakd (fig.g.;r).

4 INSTALLING THE BOILER
4.1
4.2
A Vertkd flat area k required for the boiler: 1122 mm high x 591 mm wide (44 in x 23.25 in). The surfaceon which the
boiler is mounted must be of a non reverberating and of a non combustible materiai. The appliance is supplied in a two
cartons which contain :
11 The bdcr wltb all parts artached and fixing kit. uxaprhimg of : ,
1 - The chassiswith all funhnal parts attached.
2 - Casing comprising : 2 side panels
1 &It panel
1control panel
3 - Top support plate :
4 - Box containing : water cormectionsand washers
gasconnection and 6ltec’washer
control knob and gasservicetap
safktyvabe
wan plugs
saews and fixings.
2) The hohntaf floe assembly coom~ of:
1 - RueTm and Flue duct section :
-Plasticwaulinerwithterminai
7Pbstic turret cover ( garden)
2-Fkticbagamtaining:fIu2lockingring
-‘(y&q
- 2 gaskets : one cork and one rubber
- 4 mounting saews
3 - The vrrtical flue d8ptor amlprising
- adaptor assembly
- 2 gaskets : one cork and one rubber
- 4 mounting screws
NB. (i) Flue accessories are not supplied as standard, and must be ordered to suit (seesection 1.4)
PosMoning the bo&!f
0107,,1, .
--- -T- --
‘. .’ ;F
169.5
c----- &- ““,
f
I
a) Select the location for the boiler referring to the
dimensions shown in 1.1 and 1.3 terminal location
pdtions (2.4 - Eg. 10). b) Check flue length (see 1.4 -
6gs.2 and 3).
c) Check clearance on external wall for flue terminal
position (see table 2.4 - 6g. 10)
Fig. 18
Rear outlet LIrrc
a)MarkverticaicentreIineforboiIeronwalL
b) Mark horizontal centre iine for 107 mm (4.2 in) dia
flueopening and one for bracket 6xing screws (A).
c) Using bracket as template mark 2 Exingpoints (A).
cf)ya. $ for the ffueopening using a 107 mm (4.2
c) DdI 2 fixing holes (A) and (B) 7.9 mm W16 in) and
plug.
N.B. Ensure bucket is hodzontal before tightening.
16