Halstead EDEN X Type VBX 30 User guide

OPEN VENT CONDENSING BOILER
INSTALLATION AND SERVICING INSTRUCTIONS
TO BE GIVEN TO THE USER
G.C. Appliance No. 41-260-15 (Eden VBX 18)
G.C. Appliance No. 41-260-14 (Eden VBX 30)
G.C. Appliance No. 41-260-18 (Eden VBX 18 Propane)
G.C. Appliance No. 41-260-17 (Eden VBX 30 Propane)
0086
EC 87/BP/35
Eden X Type
VBX 18 & 30
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The Halstead VBX range are high efficiency condensing, fully automatic,
wall mounted gas appliances suitable for either room sealed or opened
flued applications, for use with natural gas (G20) and LPG (G31). They
are designed for use with either sealed or open vented central heating
systems.
The appliances feature an attractive white powder coated casing, with
inset control panels. The flue systems are in white powder coat to give
a clean attractive appearance to the installation.
A telescopic horizontal concentric air/flue duct terminal is available,
suitable for room sealed applications. The duct assembly is connected
to the appliance via a turret, which can be orientated to provide different
horizontal duct directions. Extension ducts may be fitted in accordance
with and up to the maximum dimensions stated in these instructions.
A vertical concentric outlet kit is also available for installations where an
outside wall is not accessible or where it is desired to fit the duct
'through the roof'. Installation using the horizontal duct is described in
the main text of these instructions and additional information is provided
in the vertical outlet kit for the vertical installation option. (Note: If the
vertical outlet kit is to be used, access to the roof is necessary).
Other flue kits are available for open flued (B23), split flued (C53), and
special (C13) applications, contact Halstead Glen Dimplex service
helpline Tel: [phone], for further details, ONLY APPROVED FLUE
KITS OR EXTENSIONS MAY BE USED WITH THESE APPLIANCES.
INTRODUCTION
1
CONTENTS INTRODUCTION
1
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1.1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Gas Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Overall Dimensions & Minimum Clearances. . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Concentric Air / Flue Duct Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.6 Additional Concentric Flue Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Appliance Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Statutory Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Appliance Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Flue Terminal Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4 Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 Condensate Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.6 Gas Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.7 Central Heating System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.8 Draining Tap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.9 Safety Valve Open Vented System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.10 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.11 Flow Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.12 Water Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.13 Open Vented Hot Water System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.14 Domestic Hot Water Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.15 Sealed Hot Water Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.16 Safety Valve Water System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.17 Expansion Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.18 Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.19 Water Makeup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.20 Filling a Sealed Water System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.21 Electricity Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.22 External Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4 Appliance Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.1 Unpacking The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Preparing The Wall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Mounting The Appliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 Central Heating Service Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.5 Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6 Condensate Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7 Air / Flue Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.8 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5 Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 Filling the Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.2 Commissioning the Appliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4 Lockout/Reset Indication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.5 Frost Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.6 Overheat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7 Other Features: Anti Cycle Device, CH Soft start Device, Service Mode. . . 22
5.8 Users Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.9 Appliance Log Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.10 Gas Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 Routine Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Combustion Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2 Gas Control Valve, Fan & Burner Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.3 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.4 Ignition & Detection Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.5 Combustion Chamber & Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.6 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.7 Sealed Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.8 Re-assembly & Re-commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.9 Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7 Internal Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1 Functional Flow Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8 Fault Finding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.2 Diagnostic LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.3 Faulting Finding Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.4 Central Heating Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9 Replacement Of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.1 Ignition and Detection Electrodes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.2 Ignitor Unit and Ignition Leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.3 Gas Control Valve including Air Inlet Cowl. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.4 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.5 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.6 Combustion Chamber Front Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.7 Combustion Chamber Rear Insulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.8 Heat Exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.9 Flue Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.10 Water Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.11 Flue Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.12 Condensate Drain System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.13 Control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10 Short Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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IT IS A STATUTORY REQUIREMENT THAT ALL GAS APPLIANCES ARE
INSTALLED BY COMPETENT PERSONS, (i.e. CORGI REGISTERED
INSTALLERS) IN ACCORDANCE WITH THE GAS SAFETY (INSTALLATION
AND USE) REGULATIONS (CURRENT EDITION). FAILURE TO COMPLY
WITH THESE REGULATIONS MAY LEAD TO PROSECUTION.
These appliances have been tested and certified in order to satisfy the
necessary European Directives and comply with the latest Building
Regulations, including the efficiency requirements of the SEDBUK
scheme.
Gas Appliance Directive 90/396/EEC
Efficiency of Hot Water Boilers Directive 92/42/EEC
Low Voltage Directive 93/68/EEC
Electromagnetic Compatibility Directive 92/31/EEC
No modifications to these appliances should be made unless they are
fully approved by the manufacturer.
Appliance installation must be carried out by a competent person and
must be in accordance with the current legislation in force at the time of
installation, in the country of destination.
The manufacturer's instructions must not be taken as overriding any
statutory requirements.
GAS LEAKS. DO NOT OPERATE ANY ELECTRICAL
SWITCHES, OR USE A NAKED FLAME. TURN OFF THE
GAS SUPPLY. VENTILATE THE AREA BY OPENING
DOORS AND WINDOWS. CALL OUT YOUR LOCAL GAS
SUPPLIER TEL: [phone].
Control of Substances Hazardous to Health
Under Section 6 of the Health and Safety at Work Act 1974, it is required
to provide information on substances hazardous to health.
The adhesives and sealants used in this appliance are cured and give no
known hazard in this state.
Insulation Pads - These can cause irritation to skin, eyes and the
respiratory tract. If you have a history of skin complaints you may be
susceptible to irritation. High dust levels are usual only if the material
is broken. Normal handling should not cause discomfort, but follow
normal good hygiene and wash your hands before eating, drinking or
going to the lavatory. If you do suffer irritation to the eyes or severe
irritation to the skin seek medical attention.
Gas and Electricity Consumer Council (Energywatch)
Energywatch is an independent organisation, which protects the
interests of gas users. If you need advice concerning energy issues, they
may be contacted on their consumer help line number: 08459 060708, or
via their web site;
http://www.energywatch.org.uk.
The appliances incorporate a microprocessor based, fully modulating
air/gas ratio control system with direct burner ignition, which provides
a modulated heat output to central heating (CH) demand, and with
internal frost protection provided as standard.
The heat exchanger is constructed from stainless steel, and there is the
option for routing the flow and return connections either via top or
bottom connections.
The appliance may be used with any certified mains voltage room
thermostat, and can operate without the need for an automatic bypass
valve in the CH circuit, however, it is recommended that one radiator in
the room where the room thermostat is fitted is installed without
thermostatic radiator valves to allow the pump overrun facility to
operate correctly.
WHEN INSTALLING, COMMISSIONING OR SERVICING A
GAS APPLIANCE THAT INCORPORATES A PRE-MIX
BURNER AND ZERO-SET GOVERNOR, BECAUSE IT IS
NOT POSSIBLE TO MEASURE AN OPERATING
PRESSURE THE ENGINEER SHOULD FIRST CHECK
THAT THE GAS SUPPLY IS METERED AND ASCERTAIN WHETHER IT IS
POSSIBLE TO MEASURE THE GAS RATE. IF THE GAS INPUT RATE CAN
BE MEASURED THEN THE REQUIREMENTS OF GSIUR 26(9) CAN BE
MET, INCLUDING ANY SPECIFIC REQUIREMENTS IN MANUFACTURER’S
INSTRUCTIONS.
IF GAS INPUT RATE CANNOT BE MEASURED THEN, TO SATISFY THE
INTENT OF GSIUR 26(9), THE ENGINEER SHALL MEASURE THE
COMBUSTION QUALITY OF THE APPLIANCE IN ACCORDANCE WITH BS
7967 OR THE MANUFACTURER’S INSTRUCTIONS.
IF THE ENGINEER DOES NOT HAVE THE REQUIRED EQUIPMENT AND
NO ALTERNATIVE TEST IS SPECIFIED BY THE MANUFACTURER THEN
THE APPLIANCE SHALL BE TURNED OFF AND DISCONNECTED AS AN
UN-COMMISSIONED APPLIANCE UNTIL SUCH TIME THAT EQUIPMENT
IS AVAILABLE TO UNDERTAKE SUCH TESTS.
IMPORTANT INFORMATION
1.1
GENERAL DESCRIPTION
1.2
!
1
!
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2
TECHNICAL SPECIFICATIONS
GAS CATEGORIES
2.1
PERFORMANCE DATA
2.2
These appliances are certified to comply with the requirements of EN
483, EN 677, and EN 625 for use in GB and IE (Great Britain and Ireland)
using the following gas categories:
Eden VBX 30, Eden VBX 18:
II2H3P (G20 with a governed gas supply at 20 mbar (8 in.wg) inlet
pressure).
Eden VBX 30 Propane, Eden VBX 18 Propane:
II2H3P (G31 (Propane) with a regulated gas supply at 37 mbar (14.9 in.wg)
inlet pressure).
The appliance classification (as defined in EN 483) may be any of the
following depending on the chosen flue option: C13, C33, C53, or B23
2
Appliance VBX30 VBX18 VBX30 VBX18
Propane Propane
Mode Rate
Central Heating Output Max kW 30.0 18.0 30.0 30.0
(non-condensing) (Btu/h) (102400) (61400) (102400) (61400)
(80 - 60 °C) Min kW 8.2 5.9 8.2 5.9
(Btu/h) (28200) (20100) (28000) (20100)
Central Heating Output Max kW 32.1 19.3 32.1 19.3
(condensing) (50 - 30 °C) (Btu/h) (109500) (65900) (109500) (65900)
Net kW 30.4 18.4 30.4 18.4
Central Heating Input (Btu/h) (103700) (62800) (103700) (62800)
Max Rate Gross kW 33.8 20.4 33.0 20.0
(Btu/h) (115300) (69600) (112700) (68300)
Net kW 7.6 5.5 7.6 5.5
Central Heating Input (Btu/h) (26000) (18800) (26000) (18800)
Min Rate Gross kW 8.4 6.1 8.3 6.0
(Btu/h) (28600) (20800) (28300) (20500)
Central Heating Gas Rate m3/h 3.22 1.95
(after 10 min operation - hot) Max (ft3/h) (113.7) (68.9)
kg/h 2.36 1.43
Seasonal Efficiency % 90.4 90.3 92.4 92.3
Seasonal Efficiency (SEDBUK) Band “A”
Nox Classification Class “5”
Min Central Heating System Pressure (Head) Bar 0.1 (1m H2O)
Max Central Heating System Pressure (Head) Bar 3.0
Max Central Heating Flow Temperature °C 80
Min Central Heating Flow Temperature °C 30
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GENERAL SPECIFICATIONS
2.3
Natural Gas and Propane versions
Appliance VBX30 VBX18
Total weight (full) kg 38.1 32.6
Total weight (empty) kg 36.1 31.3
Max lift weight kg 28.1 24.7
Total water capacity l 2.0 1.3
Electrical supply 230V 50Hz Fuse at 3A
Internal fuse T4H 4A 250V
Maximum power consumption W 47 30
IP Rating IP20
Flue gas temperature Nat Gas 80/60 (Propane) °C 73 (76) 74 (72)
Flue gas temperature Nat Gas 50/30 °C 41 43
CO2value max rate (Nat Gas) %9.2 ± 0.3 case on
9.0 ± 0.2 case off
CO2value min rate (Nat Gas) ref only % 8.9 ± 0.1 8.4 ± 0.1
CO value max rate (Nat Gas) % 0.01 ± 0.005
CO2value max rate (Propane) %10.7 ± 0.3 case on
10.5 ± 0.2 case off
CO2value min rate (Propane) ref only % 10.0 ± 0.1 9.7 ± 0.1
CO value max rate (Propane) % 0.019 ± 0.005
Flue products mass flow rate g/s 13.7 8.3
Flue products mass flow rate (Propane) g/s 13.7 8.3
Gas Valve Offset @ min rate Pa -3.0
3
Connections
Gas 15mm compression
CH Flow 22mm tail
CH Return 22mm tail
Condensate Drain 21.5 - 22mm plastic overflow pipe
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OVERALL DIMENSIONS AND MINIMUM CLEARANCES
2.4
1
CONCENTRIC AIR / FLUE DUCT SPECIFICATIONS
2.5
The EDEN 'x-type' range can be installed to a number of different
concentric flue systems. The different flue applications as shown
in Figure 2 are available as kits usually comprising the connecting parts
to the appliance and end terminal. Flue extension ducts and extension
elbows are available as accessories.
4
Vertical flue kit - Part no. 956081
with flat roof flashing plate
Vertical flue kit - Part no. 956081
Flue system application
Vertical flue kit - Part no. 956081
Split pipe vertical flue outlet kit
- Part no. 956080
with flat roof flashing plate
Raised external flue outlet kit
- Part no. 956084
Chimney flue liner kit
- Part no. 956082
External vertical flue kit
- Part no. 956085
Telescopic horizontal flue kit
- Part no. 956120
2FLUE OPTIONS
The following systems are available for the EDEN ‘x-type’ range.
ABCDEFGHI JKLM
EDEN VBX18 320 280 150 97 100 694 200 540 400 200 5 5 200
EDEN VBX30 360 320 150 97 100 694 200 540 400 200 5 5 200
A
B
C
DE
F
H
G
I
J
K
L
M
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KIT A + TELESCOPIC HORIZONTAL WALL
TERMINAL (C13) - PART NO. 956120
2.5.1
KIT B VERTICAL CONCENTRIC FLUE
TERMINAL (C33) - HBL PART 956081
2.5.2
Traditional concentric flue system, Figure 3a, with a maximum length
of 10m*. The flanged flue elbow is designed with 3° slope towards the
appliance so that the condensate can easily drain off. It has to be
considered that for every metre horizontal flue length the terminal exit
centreline is approx. 45 mm higher than the elbow’s centreline. The
standard telescopic terminal is 615mm max length and 430mm min
length, but can be cut to a minimum flue length of 250mm, which is
suitable for single, 100mm (4"), brick walls.
Standard concentric (ø100/60) vertical flue application, Figures 3b, 3c,
through roof attics with a maximum length of 12m*. The kit comprises
of the roof terminal, vertical adaptor with sampling point and bracket.
The maximum length is measured from the top of the appliance casing
to the underside of the air cowl.
The maximum length is measured from the top of the appliance casing
to the underside of the air cowl.
For installation details refer to the flue kit instructions.
* Note: Flues which exceed 7mtrs in length will be subject to a small
percentage decrease in heat input (below the standard tolerance) as
shown in graph ‘A’ below.
3a
3b
5
3c a
b
Roof terminal
with rain
cover and
pitched roof
flashing kit.
Fig 3(c) Offset vertical flue.
‘a’ measured from boiler flue outlet centre line to the centre line of
the extension elbow.
‘b’ measured from the top of the boiler to the underside of the air cowl.
Maximum allowable length of a + b = 8900mm
KIT C: HORIZONTAL ANTI-PLUME
FLUE KIT (C13) - PART NO. 956084
2.5.3
If the standard horizontal terminal is likely to cause nuisance to a
neighbour or buildings, because of excess pluming, then this particular
flue kit raises the flue gas outlet point to a higher elevation with the
minimum amount of changes. The flue gas duct is teed-off from the
concentric part and covered by an 80mm outer tube to protect the flue duct
from freezing. The air in-take remains at the lower level (see Figure 3d).
If choosing this option then the external flue duct length should be taken
into account when calculating equivalent flue length.
For installation details refer to the flue kit instructions.
Horizontal flues ( C33 ) up to 10m in length, or equivalent, may be
used, however a reduction in the heat input will occur. The graph
shows details.
102.0
101.0
100.0
99.0
98.0
97.0
96.0
95.0
94.0
93.0
92.0
0123456789 1011
Flue Length (m)
Heat input (%)
Reduction in heat input as flue length increases
GRAPH A
SINGLE PAGES 20/9/10 09:59 Page 7

3d
KIT D EXTERNAL VERTICAL FLUE - (C33)
PART NO. 956085
2.5.4
3e
Suitable for installations if the appliance can’t be repositioned and
where other horizontal flue options may causes some nuisance to
neighbours or buildings. The flue kit contains some additional 45°
elbows and extension ducts as well as a special wall bracket to pass the
guttering (see Figure 3e). The concentric flue will be routed vertically
alongside the outside wall to above the roofline. Special seals are
required to prevent rainwater penetrating the pipe joints.
For installation details refer to the flue kit instructions.
6
KIT E CHIMNEY FLUE LINER KIT
(B23) - PART NO. 956082
2.5.5
This kit is suitable for open flue application in accordance with BS5440
where a room sealed flue installation is impractical. The kit comprises of
a flue adaptor from the appliance to the chimney, a flexible plastic flue
liner with connection parts and chimney terminal (see Figure 3f). Where
an open flue system is used, then an air vent must be provided in the
same room or internal space as the flue duct air inlet, see section 3.4.
For installation details refer to the flue kit instructions.
Max flexi liner length = 30mtrs
Min flexi liner length = 5mtrs
Max concentric length = 2000mm
Min concentric length = 100mm
3f
A flue system can be built up from the components
detailed in the table on the next page, but the total
flue resistance must not exceed the maximum
stated.
SINGLE PAGES 20/9/10 09:59 Page 8

FLUE LENGTHS
Length supplied in standard kit - horizontal 815mm
Max horizontal length (from boiler to chimney - 60/100mm) 2000mm
Min horizontal length (from boiler to chimney - 60/100mm) 100mm
Max vertical length (from boiler to chimney - 60/100mm) 2000mm
Min vertical length (from boiler to chimney - 60/100mm) 200mm
Length supplied in standard kit - vertical (available in 10m, 20m and 30m length) N/A
FLEXITUBE MUST BE PURCHASED AS AN ACCESSORY TO COMPLETE THE KIT (See below)
Flexi tube min length 5m
Flexi tube max length 30m
ACCESSORIES
Description Part No. Resistive Length
HORIZONTAL - 60/100 Accessories
Flue extension duct - 500mm 956092 450mm
Flue extension duct - 1000mm (Incl. 1 x support bracket) 956093 950mm
93° extension elbow 956091 1550mm
45° extension elbow (pair) 956090 775mm
Air inlet duct - included in kit N/A N/A
Straight adapter (60/80) - included in kit N/A N/A
91.5° adapter elbow (80/80) - included in kit N/A N/A
Support bracket - 100mm 840517 N/A
93° flanged elbow - included in kit 956082 N/A
Vertical turret socket 956087 N/A
VERTICAL - Accessories
Flexi tube - 10m 956110 10m
Flexi tube - 20m 956111 20m
Flexi tube - 30m 956112 30m
Straight duct (80) - included in kit N/A N/A
Chimney terminal - included in kit N/A N/A
NOTE: RESISTIVE LENGTH INFORMATION ONLY REQUIRED FOR COAXIAL FLUE PARTS. THE CORRUGATED (FLEXI TUBE)
FLUE PARTS ARE FIXED AND ALL PARTS ARE REQUIRED FOR EVERY APPLICATION.
7
SINGLE PAGES 20/9/10 09:59 Page 9

KIT F: TWIN FLUE SYSTEM (C53)
PART NO. 956080
2.5.6
This flue system kit is designed for installations where the air intake
position is different than the flue duct exit point. The kit comprises of a
twin adaptor from which the air intake is taken from the adjacent outside
wall (see example Figure 3g) and the flue duct is routed vertically
through the roof.
It has to be noted that the flue duct is under pressure when the appliance
is in operation and the duct can leak poisonous carbon monoxide if the duct
components are not correctly assembled. It is not recommended to route
the flue duct through living space areas, i.e. bed rooms, living rooms etc.
For installation details refer to the instructions provided with the twin
flued kit.
For C53 flue systems the terminal for the supply of combustion air and
for the evacuation of combustion products shall not be installed on
opposite walls of the building.
Maximum flue resistance permitted for a twin flued system
= 52 Pa
Minimum flue resistance permitted for a twin flued system
= 23.5 Pa
3g
A flue system can be built up from the components
detailed in the table, but the total flue resistance
must not exceed the maximum stated.
ADDITIONAL CONCENTRIC FLUE KITS
2.6
The following additional concentric kits are available as optional extras.
Flue Extension Ducts - 1000 mm and 500 mm long, (each duct extends
the flue length by up to 950 mm and 450 mm respectively).
93° Extension Elbow - Allows an additional bend in the flue, and has an
'equivalent length' of 1550 mm. This elbow is mechanically different
from the flanged elbow supplied as standard with the appliance, but has
the same equivalent length.
45° Extension Elbow - Allows an additional bend in the flue and has an
'equivalent length' of 775 mm.
Vertical Turret Socket - For use with elevated horizontal flues and
vertical terminals.
Vertical Roof Terminal - For use where an external wall is not available,
or where it is desirable to route the ducts vertically.
For installation details refer to the instructions
provided with the individual flue kits.
These optional kits may be used with the standard flue kits to produce an
extensive range of flue options, providing that the following rules are
strictly obeyed.
a) The maximum/minimum permissible length of the room sealed flue
system are:
Horizontal flue terminal (all orientations) maximum 10000 mm (197 in)
Horizontal flue terminal (rear exit) minimum 250 mm (10 in)
Vertical flue terminal maximum 12000 mm (472 in)
Vertical flue terminal minimum 600 mm (231/2in)
The 'equivalent' flue length must not exceed the
maximum values stated.
b) The standard terminal must always be fitted horizontally; horizontal
ducts must have a continuous fall towards the appliance of 2.5°. This
ensures condensate runs back into the appliance from the flue
system. The vertical terminal must always be used if a vertical
outlet is required.
c) The concentric flue system must use either a flanged elbow or a
vertical flue turret socket at the entry/exit to the appliance.
d) All joints must be correctly made and secured in accordance with
the installation instructions. When cutting ducts, avoid swarf,
uneven and sharp edges to maintain duct integrity.
Refer to Figures 2 and 3 to determine which option
kits are required before commencing the installation.
Instructions for installing the appliance with a
horizontal flue and straight extension ducts are
included in the main text of these instructions
(section 4.8).
Flue Component Flue Resistance (Pa) Part Number
Twin Flue Adaptor (required) 9.5 -
Air Inlet Terminal (required) 3 -
Chimney Terminal (required) 0.5 -
80 mm dia straight duct 1 metre 1 956101
80 mm dia straight duct 2 metre 2 956102
90° Elbow (80/80) 8 956100
45° Elbow (80/80) 4 956099
8
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PLUME DIVERTER
TERMINAL INSTALLATION
INSTALLATION INSTRUCTIONS
2.6.1
Plume Diverter Kit Part No: 956103
(For use with Standard horizontal flue kit - Part no 956083 - only)
This kit is provided to assist in fitting a condensing boiler with reduced
clearances when fitted in good practice according to the Guide to
Condensing Boiler Installation published by DEFRA/HMSO.
This kit allows the boiler flue outlet to be directed to the left or to the
right only.
Under certain operating conditions condensing appliances have a tendency
to form a plume of water vapour at the terminal. Therefore consideration
should be given when fitting the Plume Diverter in terms of plume
dispersal onto adjacent surfaces and neighbouring properties.
a) Refer to section 2.5 for instructions on fitting the flue system.
Also see Figure 5 for all other clearances.
3h
The resistance of the diverter is equivalent to 0.5
metre of flue length. Ensure this is used when
calculating the maximum allowable flue length.
(maximum horizontal flue length restricted to 9.5
metres when using the plume diverter).
The diverter allows the terminal clearance to be reduced as follows (see
diagrams below):
Clearance H – From a surface facing the terminal - 600mm.
Clearance F – From internal or external clearances - 300mm.
b) Choose the direction required to deflect the flue products
(left or right only)
c) Push the diverter elbow onto the angled outlet of the flue terminal
in the desired rotational position and ensure the diverter is pushed
up to the shoulder to fully engage the rubber seal.
d) Fix the diverter to the flue terminal with the self drilling screw
provided. Do not use a power tool to fit screw.
3i
Note.
The Plume Diverter terminal must not under any
circumstances deflect flue products downwards.
9
SINGLE PAGES 20/9/10 09:59 Page 11

APPLIANCE HYDRAULIC CIRCUITS
2.7
4
FLUE
PRODUCTS
PRIMARY HEAT
EXCHANGER
BURNER &
BURNER
FLANGE
CH FLOW
THERMISTOR
CH RETURN
THERMISTOR
CH RETURN
CH FLOW
CONDENSATE
OUTLET
CONDENSATE
TRAP
CH RETURN
CH FLOW
10
SINGLE PAGES 20/9/10 09:59 Page 12

3
INSTALLATION REQUIREMENTS
STATUTORY REQUIREMENTS
3.1
FLUE TERMINAL POSITION
3.3
GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1996 (AS
AMENDED)
The appliance is suitable only for installation in GB and IE and should
be installed in accordance with the rules in force.
In GB, a CORGI Registered Installer must carry out the installation. It
must be carried out in accordance with the relevant requirements
of the:
Gas Safety (Installation and Use) Regulations
The appropriate Building Regulations either The Building Regulations,
The Building Regulations (Scotland), Building Regulations (Northern
Ireland).
The Water Fitting Regulations or Water Byelaws in Scotland.
The Current I.E.E Wiring Regulations.
Where no specific instructions are given, reference should be made to
the relevant British Standard code of Practice.
In IE, the installation must be carried out by a Competent Person and
installed in accordance with the current edition of I.S.813 “Domestic
Gas Installations”, the current Building Regulations and reference
should be made to the current ETCI rules for electrical installation.
It should also be in accordance with the relevant recommendations in
the current editions of the following British Standards and Codes of
Practice: BS 5449, BS 5546, BS 5440-1, BS 5440-2, BS 6798, BS 6891,
Institute of Gas Engineer document IGE/UP-7, BS 7074 (expansion
vessel), BS 5482 (propane installations) and IS813 for IE.
IMPORTANT NOTE: Manufacturer's instruction must NOT be taken in
any way as overriding statutory obligations.
APPLIANCE LOCATION
3.2
THE FOLLOWING LIMITATIONS MUST BE OBSERVED WHEN SITING
THE APPLIANCE:
a) The appliance is not suitable for external installations. The position
selected for installation should be within the building, unless
otherwise protected by a suitable enclosure and MUST allow
adequate space for installation, servicing and operation of the
appliance and for air circulation around it (Section 2.4 and 3.4).
b) This position MUST allow for a suitable flue system and terminal
position. The appliance must be installed on a flat vertical wall,
which is capable of supporting the weight of the appliance and any
ancillary equipment.
c) If the appliance is to be fitted in a timber framed building it should
be fitted in accordance with the British Gas publication 'Guide for
Gas Installations In Timber Frame Housing', Institute of Gas
Engineers document IGE/UP-7. If in doubt, advice must be sought
from the Local Gas Supplier.
d) The appliance is approved to a protection rating of IP20. Therefore
if the appliance is to be installed in a room containing a bath or a
shower, any electrical switch or control utilising mains electricity
must be so situated that it cannot be touched by a person using the
bath or shower. Attention is drawn to the requirements of the
current BS 7671 (I.E.E Wiring Regulations) and in Scotland the
electrical provisions of the Building Regulations applicable in
Scotland.
DETAILED RECOMMENDATIONS FOR FLUE INSTALLATION ARE
GIVEN IN BS 5440-1. THE FOLLOWING NOTES ARE FOR GENERAL
GUIDANCE.
a) The appliance MUST be installed so that the terminal is exposed to
the external air.
b) It is important that the position of the terminal allows free passage
of air across it at all times.
c) It is ESSENTIAL TO ENSURE that products of combustion
discharging from the terminal cannot re-enter the building or any
other adjacent building, through ventilators, windows, doors, other
sources of natural air infiltration, or forced ventilation / air
conditioning.
d) The minimum acceptable dimensions from the terminal to
obstructions and ventilation openings are specified in Figure 6.
e) If the terminal discharges into a pathway or passageway check that
combustion products will not cause nuisance and that the terminal
will not obstruct the passageway.
f) Where the lowest part of the terminal is fitted less than 2000 mm (78
in) above the ground, above a balcony or above a flat roof to which
people have access, the terminal MUST be protected by a purpose
designed K6 terminal guard (optional extra: Part No. 951507).
g) The air inlet / flue outlet MUST NOT be closer than 25 mm (1 in) to
combustible material.
h) Condensing appliances have a tendency to form a plume of water
vapour at the terminal under certain operating conditions. This is
normal but positions where this would cause damage or a nuisance
should be avoided. Consideration should be given to the dispersal of
the plume in terms of adjacent surfaces and neighbouring
properties. A special flue terminal, (Kit C), is available to raise the
flue discharge point; use of this terminal will limit the maximum
flue length available.
For further information contact: Halstead Glen Dimplex service
helpline Tel: [phone].
VENTILATION REQUIREMENTS
3.4
Detailed recommendations for air supply are given in BS 5440-2.
The following notes are for general guidance.
a) It is not necessary to have a purpose provided air vent in the room
or internal space in which a room-sealed appliance is installed.
b) Cupboard or compartment ventilation is not necessary for a room-
sealed appliance providing that the minimum clearances are
maintained.
c) Where an open flued, (B23), system is used, then an air vent must be
provided in the same room or internal space as the flue duct air
inlet, with a minimum free-area of at least:
VBX 30 117 cm2
VBX 18 57 cm2
d) If the appliance is installed in a room or internal space with other
opened flued appliances, then the size of the air vent necessary
should be calculated in accordance with BS 5440-2 Table 2.
11
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5
FLUE TERMINAL POSITION
SPECIAL REQUIREMENTS FOR A
VERTICALLY BALANCED FLUE
Position Minimum spacing
ADirectly below an openable window, 300mm 12in
air vent, or any other ventilation
opening
BBelow gutter, drain/soil pipe 75mm 3in
C Below eaves 200mm 8in
DBelow a balcony 200mm 8in
*2500mm 98in
EFrom vertical drain pipes and 150mm 6in
soil pipes
F From internal or external corners 300mm 12in
*internal corners *1000mm 40in
GAbove adjacent ground or
balcony level 300mm 12in
H From a surface facing the terminal 600mm 24in
*2500mm 98in
I Facing terminals 1200mm 48in
*2500mm 98in
JFrom opening (door/window) in 1200mm 48in
carport into dwelling *not recommended
KVertically from a terminal on the 1500mm 60in
same wall
LHorizontally from a terminal on the 300mm 12in
same wall
MAdjacent to opening 300mm 12in
NBelow carport 600mm 24in
*not recommended
OFrom adjacent wall 300mm 12in
PFrom adjacent opening window 1000mm 40in
Q From another terminal 600mm 24in
RMinimum height 300mm 12in
*Recommended by the boiler manufacturing industry to prevent pluming
nuisance and damage to buildings.
e) Where an open flued system is used, and the flue duct air inlet is
within a compartment then high and low level air vents are
necessary in the compartment, the size of the vents should be
calculated in accordance with BS 5440-2 Table 2.
CONDENSATE DISPOSAL
3.5
The condensate drain connection is suitable for either 21.5 mm or 22
mm plastic push fit or adhesive overflow pipes and fittings. It should
be piped to drain, preferably within the building, maintaining a
continuous 2.5° fall away from the appliance. If the drain is routed to
outside it should be to a drain or soak away, and any external pipe
work should be in 32 mm. Insulation to protect from freezing in cold
weather conditions is also advisable. Note if the appliance is installed
in a garage all pipe work should be in 32 mm. Ensure that the
condensate discharge system complies with any local regulations in
force.
GAS SUPPLY
3.6
a) The Gas Supplier should be consulted at the installation planning
stage in order to establish the availability of an adequate supply
of gas.
b) An existing service pipe MUST NOT be used without prior
consultation with the Gas Supplier.
c) A gas meter can only be connected by the Gas Supplier or by
their contractor.
d) An existing meter and/or pipe work should be of sufficient size
to carry the maximum appliance input plus the demand of any
other installed appliance. (BS 6891: 1988).
A minimum of 22 mm diameter pipe work is recommended within
1000 mm of the appliance gas cock.
e) Natural gas appliances: The governor at the meter must give a
constant outlet pressure of 20 mbar (8 in.wg) when all appliances
on the system are running.
Propane appliances: The regulator must give a constant outlet
pressure of 37 mbar (14.9 in.wg) when all appliances on the
system are running.
f) The gas supply line should be purged. WARNING: Before purging
open all doors and windows, also extinguish any cigarettes,
pipes, and any other naked lights.
g) The complete installation must be tested for gas tightness.
CENTRAL HEATING SYSTEM
3.7
a) The appliances incorporate all the components necessary to allow
them to be connected to a sealed central heating system. Refer to
Figure 7a for a typical system design, which incorporates
radiators, and a drain facility that must be provided at the lowest
point in the system to allow complete drain down.
b) The installation should be designed to operate with a flow
temperature of up to 95 °C.
c) A sealed system must only be filled by a competent person.
d) The available pump head for the appliances are given in
Figure 6.
e) If thermostatic radiator valves are fitted, a radiator must be fitted
with two lock shield valves, to enable correct operation of the
pump-overrun facility.
12
SINGLE PAGES 20/9/10 09:59 Page 14

f) The following paragraphs outline the specifications of the items
fitted to the appliances.
PUMP - The available pump head shown in Figure 6 is that in excess of
the appliance hydraulic resistance, i.e. that available for the system.
0
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
0.5
1
1.5
2
2.5
3
3.5
4
Flow Rate ltr/min
Pressure Drop (m H
2
O)
6
APPLIANCE HYDRAULIC RESISTANCE
VBX 30
VBX 18
DRAINING TAP
3.8
A draining tap must be provided at the lowest point of the system, which
will allow the entire system and hot water system to be drained.
Draining taps shall be to the current issue of BS 2879.
SAFETY VALVE OPEN VENTED SYSTEM
3.9
A safety valve need not be fitted to an open vented system. (See 3.16 for
sealed systems)
PUMP
3.10
The pump should be fitted on the flow pipe from the boiler and have
isolating valves each side.
A variable duty pump should be set to give a temperature difference of
no greater than 20°C between the flow and return, with the thermostat
set at “MAX”, which is approximately 80° to give a flow rate as shown in
table 1.
See figure 6 for pressure loss of the boiler.
High resistance microbore systems may require a higher duty pump.
FLOW RATE
3.11
If it is necessary to alter the flow rate, the system can be fitted with a
lockable balancing valve in the main flow or return pipes shown as valve
“A” in figure 7. The flow rate through the boiler must not be allowed to
fall below that given in table 1.
WATER TREATMENT
3.12
WATER TREATMENT, CLEANSING AND FLUSHING THE HEATING
SYSTEM
NOTE: British Standard BS7593: 1992 stresses the importance of
cleansing and flushing of the system to ensure it continues to run
efficiently with the minimum of maintenance necessary. Halstead
Boilers fully support this professional approach and recommend that
the system is cleansed with an effective chemical cleanser and
protected long term with a suitable inhibitor. Such products are available
from Fernox and Sentinal.
Table 1. Flow Rate
MINIMUM FLOW RATE
200 l/h
This is equal to 20°C differential at minimum heat input.
OPEN VENTED HOT WATER SYSTEM
3.13
The boiler must be supplied from an unrestricted water supply taken
from a feed and expansion cistern situated at a maximum height of 27
metres (90ft) above the boiler.
The cold feed must be 15mm minimum size.
The vent must rise continuously and be unrestricted.
It is important that the relative positions of the pump, cold feed and open
vent are as shown in figure 8.
DOMESTIC HOT WATER CYLINDER
3.14
SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE
The domestic hot water cylinder must be of the double feed fully indirect
coil type.
SEALED HOT WATER SYSTEMS
3.15
The installation must comply with the appropriate requirements of the
current issue of BS4814, BS5449, BS6759, BS6798 and BS7074 Part 1
and 2.
See figure 7 for a suggested layout.
SAFETY VALVE SEALED SYSTEM
3.16
A safety valve must be fitted to a sealed system.
It shall be preset, non-adjustable with a lift pressure of 3 bar,
incorporating seating of a resilient material, a test device and a
connection for drain.
The drain from the safety valve must be routed outside the building,
must not discharge above an entrance or window or any type of public
access area, be clear of any electrical fittings and positioned so that any
discharge can be seen.
13
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EXPANSION VESSEL
3.17
A diaphragm type expansion vessel, conforming to the current issue of
BS4814 (see also BS7074 Part 1 and 2) must be connected at a point
close to the inlet side of the circulating pump, see the diagrammatic
layout, figure 7 unless laid down differently by the manufacturer.
The expansion vessel volume depends on the total water system volume
and the initial system design pressure. For any system an accurate
calculation of vessel size is given in the current issue of BS5449 and
BS7074 Part 1.
Example: For an initial design pressure of 0.7 bar, the minimum total
vessel volume required is 0.063 x Total System Volume.
7
SEALED WATER SYSTEM
Expansion Vessel Requirements
Vessel charge and initial
system pressure
Total water content for
system using 8L (1.54 gal)
capacity expansion vessel
supplied with appliance
For systems having a
larger capacity, multiply
the total system capacity in
litres (gallons) by these
factors to obtain the total
minimum expansion vessel
capacity required in litres.
bar 0.5 0.75 1.0 1.5
L 96 84 73 50
0.0833 0.093 0.109 0.156
The charge pressure must not be less than the static head of the system,
that is, the height of the highest point of the system above the expansion
vessel.
The water content of the boiler is given in 2.3 General Specifications.
PRESSURE GAUGE
3.18
A pressure gauge with a set pointer and covering at least 0 to 4 bar (0 to
60 lb/in) shall be fitted permanently to the system in a position where it
can be seen when filling the system.
WATER MAKEUP
3.19
Provision should be made for replacing water loss from the system
using a make up bottle mounted in a position higher than the top point
of the system, connected through a non-return valve to the return side
of either the heating circuit or the hot water cylinder.
Alternatively, provision for make up can be made using a filling loop.
FILLING A SEALED WATER SYSTEM
3.20
Provision for filling the system at low level must be made, see figure 8.
There must be no permanent connection to the mains water supply, even
through a non-return valve.
CONTROLS. As a minimum it is recommended that a room thermostat
be installed to control the appliance. Thermostatic radiator valves may
be fitted to the system, however they must not be fitted in the room
where the room thermostat is fitted. There must be at least one radiator
installed with lock shield valves that should not be closed. Further
guidance can be obtained from the Domestic Heating and Hot Water
Guide to the building regulations.
Note: A higher initial design pressure requires a larger volume
expansion vessel.
ROOM THERMOSTAT TANK
THERMOSTAT
HOT
WATER
CYLINDER
RETURN
FLOW
DRAIN
COCK
CH/DHW
SWITCHED LIVE
CH/DHW
2 CHANNEL
PROGRAMMER
APPLIANCE
EXPANSION
VESSEL
TERMINAL
BLOCK
SAFETY
VALVE
LOCKABLE
BALANCING
VALVE “A” PUMP
PRESSURE
GAUGE
3-WAY
VALVE FILL POINT
NON-RETURN
VALVE
SYSTEM
BYPASS
MOTORISED
VALVE
AIR RELEASE
VALVE
NON RETURN
VALVE
AUTOMATIC
AIR VENT
MAKE UP BOTTLE
Observe minimum
static head requirements
NOTE: No automatic by-pass required. However,
it is recommended to leave one radiator open and
to fit a system by-pass in the DHW circuit to ensure
pump over-run functionality.
14
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15
ELECTRICITY SUPPLY
3.21
a) Wiring external to the appliance must be in accordance with the
current I.E.E Wiring regulations (BS 7671) for electrical installation
and any local regulations, which apply.
b) The mains cable must be at least 0.75 mm2 (24/0.2 mm) PVC
insulated to BS 6500 table 16.
c) THIS APPLIANCE MUST BE EARTHED. Failure to provide a
satisfactory earth connection will result in appliance malfunction.
EXTERNAL CONTROLS
3.22
d) The method of connection to the mains supply must facilitate
complete electrical isolation of the appliance. Either a 3A fused
three pin plug and un-switched shuttered socket outlet, both
complying with BS 1363, or a 3A fused double pole switch having a
3 mm contact separation in both poles and serving only the boiler
(and its external controls) may be used.
8
OPEN VENT WATER SYSTEM with flow and return connected to bottom pipes
The VBX appliances may be used with any certified programmer/room
thermostat, as described in section 4. For further information contact:
Halstead Glen Dimplex service helpline Tel: [phone].
COLD WATER
STORAGE
STOP
VALVE
TO DRAIN
OFF TAP
TANK
THERMOSTAT
HOT WATER
CYLINDER
DRAIN TERMINAL
BLOCK
ROOM
THERMOSTAT
CH/DHW
2 CHANNEL
PROGRAMMER
RETURN
FLOW
SWITCHED
LIVE
LOCKSHIELD
VALVE
SYSTEM
BYPASS
3-WAY
VALVE
MOTORISED
VALVE
MOTORISED
VALVE
APPLIANCE
AUTOMATIC
AIR VENT
EXPANSION
RECOMMENDATION ONLY
NOTE: PUMP REQUIRES
OPTIMISATION TO
PREVENT PUMP OVER
INTO FEED & EXPANSION
TANK COLD
FEED
CH FEED &
EXPANSION TANK
NOTE: No automatic by-pass
required. However, it is
recommended to leave one
radiator open and to fit a
system by-pass in the DHW
circuit to ensure
pump over-run
functionality.
COLD WATER
STORAGE
TO DRAIN
OFF TAP
STOP
VALVE
TANK
THERMOSTAT
HOT WATER
CYLINDER
DRAIN
ROOM
THERMOSTAT
CH/DHW
2 CHANNEL
PROGRAMMER
RETURN
FLOW
SWITCHED
LIVE
LOCKSHIELD
VALVE
SYSTEM
BYPASS
3-WAY
VALVE
MOTORISED
VALVE
AUTOMATIC
AIR VENT
TERMINAL
BLOCK
MOTORISED
VALVE
COLD
FEED
APPLIANCE
DRAIN
EXPANSION
CH FEED &
EXPANSION TANK
150mm MAX
OPEN VENT WATER SYSTEM with flow and return connected to top pipes
DRAIN
AUTOMATIC
AIR VENT
NOTE:- Flow
and return
pipes must be
run in copper
for a minimum
of 1.5mtrs
from the boiler.
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4
APPLIANCE INSTALLATION
UNPACKING THE APPLIANCE
4.1
Before installing the appliance, check that the chosen location is
suitable (section 3.2) and that the requirements for flue position (section
3.3) and minimum clearances (Figure 1b) are satisfied.
The appliance is supplied in one box. Flue kits are provided separately,
the various flue kits available as described in sections 2.5 - 2.7. If the
appliance is to be installed without access to an external wall, a wall
liner kit is also required.
Unpack the boxes and check the contents:
G
Complete appliance
G
Paper wall mounting template
G
Wall mounting plate
G
Installation and Servicing Instruction
G
User's Instructions
G
Warranty Card
G
Hardware pack containing:
50mm x No 10 Wood Screws - 4 off
Rawl Plug to suit - 4 off
Manual Handling Note:
During the appliance installation it will be necessary
to employ caution and assistance whilst lifting, as the
appliance exceeds the recommended weight for a
one-man lift. Take care to avoid trip hazards, slippery
or wet surfaces.
PREPARING THE WALL
4.2
a) Fix the paper template in the required position (ensuring that the
necessary clearances are achieved). Ensure squareness by hanging
a plumb line.
b) Mark the position of the wall mounting plate-fixing holes (4). Select
one from each group. Refer to Figure 10.
c) Mark the position of the flue outlet. For side flue installation extend
the flue centre line on to the sidewall, where the flue length exceeds
775 mm, a flue slope angle of 2.5° needs to be taken into account.
Refer to Figure 10. Remove the paper template.
d) Cut the hole in the wall for the air/flue duct (preferably with a core-
boring tool). The hole must be horizontal and not be less than 100
mm in diameter. If the hole is not accessible from outside, its
minimum diameter must be sufficient to allow insertion of the wall
liner (130 mm, 5in). The wall liner is available as an optional extra
and must be sealed in position with mortar (or equivalent).
e) Drill the four fixing holes using a 6mm drill and insert the wall plugs
provided.
f) Hang the wall mounting plate using two fixing screws in the top,
ensuring that it is level.
MOUNTING THE APPLIANCE
4.3
Refer to Figure 10.
a) Lift the appliance into position approximately 10 mm above the top
of the wall mounting plate and use the side wings on the plate to
locate the appliance in a horizontal direction. Then carefully lower
the appliance, ensuring that the top locating rail is securely
engaged.
b) Connect the central heating system pipes to the central heating flow
and return pipes on the boiler.
Pipe work may be routed from above or below the
appliance as required.
9
108
190
190 127.5
POSITION OF
DUCT HOLE
POSITION OF WALL
MOUNTING PLATE
2.5º
101.5
REAR FLUE SIDE FLUE
16
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17
10
MOUNTING THE APPLIANCE
WALL MOUNTING PLATE
RAIL LOCATION EDGE
CENTRAL HEATING SERVICE
CONNECTIONS
4.4
Refer to Figure 11.
a) The boiler is supplied with 22mm copper tails for both upwards and
downwards (optional) flow and return pipe routing suitable for
compression or soldering connections.
USE EXTREME CARE IF SOLDERING THE JOINTS NEAR TO THE
APPLIANCE. IF BOILER IS LOCATED IN TIGHT SPACE IT IS
RECOMMENDED TO REMOVE THE PIPES FROM THE BOILER.
b) Connect the central heating system pipes to the central heating flow
and return pipes on the boiler. If downwards routing is required:
The sealed ends must be removed before connecting to the heating
system pipes. The upwards pipes must be used for connecting to a
vent pipe (open system) or fitting to an automatic air vent (sealed
system). The remaining pipe must be solder sealed.
The flow and return sensors have to be removed from the upwards
pipes and reconnected to the downward pipes (Fig 47; flow is
nearest to the front).
c) Commission the central heating system as described in section 5.1,
and then proceed to section 4.5.
11
SERVICE CONNECTIONS
GAS CONNECTION
4.5
Refer to Figure 11.
Connect the gas supply pipe to the gas service cock. It is recommended
that a minimum of 22 mm diameter OD copper pipe be used to within
1000 mm of the gas service cock.
CONDENSATE CONNECTION
4.6
Refer to Figure 12.
Connect either a Ø21.5mm or Ø22mm plastic push fit or adhesive
overflow pipe to the condensate outlet. It should be piped to drain,
preferably within the building, maintaining a continuous 2.5° fall away
from the appliance. Note; if an additional “U” trap is fitted between the
appliance and the discharge point, then a visible air break is necessary
between the appliance and trap, because a trap is already provided
within the appliance. Ø32mm pipe should be used for external pipe
work, or if the appliance is installed in a garage. If the drain is routed
externally to a drain or soak away, then the external length should be
kept as short as possible and not exceed 3000 mm. Protection from
freezing in cold weather conditions is also advisable. Ensure that the
condensate discharge system complies with any local regulations in
force.
In exceptional circumstances, such as when a boiler is installed in a
basement without drainage, it may be necessary to install a condensate
pump to carry condensate up to ground/drain level. Such products are
available from Grundfos Pumps Ltd on: 01525 850000 and Pump House
on: 0115 922 2211.
AIR/FLUE DUCT INSTALLATION
4.7
For correct flue installation please refer to the installation instructions
that are provided with the individual flue kit as described in sections
2.5 - 2.7.
a) Measure the required flue length as shown in Figure 13. Refer to
section 2.5 to determine whether any extension kits are required.
Installations using only the standard ducts or standard ducts with
straight extensions are described in this section. Installation
instructions for all other flue systems are included in the various
flue kits.
12
CONDENSATE CONNECTIONS
CH FLOW
CH RETURN
CH FLOW (OPTIONAL)
CH RETURN (OPTIONAL)
MAINS GAS INLET
CONDENSATE OUTLET
CONDENSATE DRAIN
MUST BE ≥Ø22
WASTE STACK
2.5º
CONDENSATE
DRAIN
MUST BE ≥Ø22
2.5º
EXTERNAL PIPE MUST BE ≥Ø32mm
SINK WASTE
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b) Ensure that all (inner and outer tube) sealing rings are provided and
assemble the air/flue ducts as shown in the flue instructions.
c) Construct the correct flue length by building the flue out from the
appliance. Ensure that the flue and air seals are correctly fitted
before assembly and that each section is fully engaged.
The flue length is measured from the centreline of
the appliance flue outlet to the inside of the external
wall-sealing ring. In most cases it will be possible to
achieve the required flue length without cutting the
ducts, however where necessary the plain ends of
the extension ducts may be cut. Never cut the
swaged end, and always ensure that the cut is square
and free of burrs or debris.
NOTE IT IS ESSENTIAL THAT THE TERMINAL IS
FITTED THE CORRECT WAY UP.
See flue kit Instructions (i.e. rain shield at the top).
13
MEASURING THE EXACT FLUE LENGTH
WALL
FAN OUTLET
EXTERNAL
Dia. 60mm
L
TOTAL FLUE LENGTH
FROM OUTLET CENTRE
TO OUTSIDE WALL FACE:
= LENGTH L
14
FIBRE
SEAL FITTED
INTERNAL WALL
SEALING RING
130mm Dia.
HOLE WITH
WALL LINER
TOP
EXTERNAL WALL
SEALING RING
1 INSERT
ASSEMBLED
FLUE SYSTEM
FROM INSIDE
THE ROOM.
EXTERNAL
WALL
SEALING RING
OPENS
2ALIGN ASSEMBLED FLUE
SYSTEM ELBOW TO
APPLIANCE AND SECURE
3SLIDE
INTERNAL
WALL
SEALING RING
TO WALL TO
FORM A GOOD
SEAL
INSTALLING THE FLUE SYSTEM FROM
INSIDE THE ROOM
INSTALLING THE AIR/FLUE DUCT
FROM INSIDE THE ROOM
4.7.1
Wall thickness up to 800 mm (31in) only.
a) Push the terminal through the wall liner taking care to ensure that
the terminal is the correct way round and the external wall-sealing
ring does not become dislodged.
b) Assemble the flue system extension ducts as necessary, referring
to Figure 14.
c) Pull the flue system towards the appliance to seat the external
sealing ring against the outside wall, ensuring that the duct joints
are not disturbed.
d) Use the internal sealing ring to make good the internal hole, and
check that the terminal is correctly located on the outside wall
(Where possible this should be visually checked from outside the
building.) Figure 14 shows a view of the flue system, correctly
installed.
e) Finally locate and secure the elbow to the appliance using the four
screws provided.
INSTALLING THE AIR/FLUE DUCT
FROM OUTSIDE THE BUILDING
4.7.2
(Flue hole diameter 100 mm - wall liner not necessary)
a) Secure the flue elbow with seal to the appliance using 4 screws.
b) Fit external wall sealing ring over flue and then from outside the
building, push the flue system through the wall taking care to
ensure that the terminal is the correct way around.
c) Loosely fit the internal wall sealing ring over the inside end of the
flue.
d) Assemble the flue system extension ducts as necessary, referring
to the flue kit instructions, and fit to the flue elbow.
e) Fit the flue terminal to the flue system, ensuring that the duct joints
are not disturbed, and that the external sealing ring is seated
against the outside wall.
f) Finally use the internal sealing ring to make good the internal hole.
Check that the external wall sealing ring and the terminal is
correctly located, on the outside wall from outside the building.
18
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