Myson Apollo 30Si User guide

lWYSOnr
HEATIh'G
4UC3r24
-01
for.
the
Apollo
30Si,40Siand
50Si
wallmounted
gas
boilers
G.C.ApplianceNo's.
Apollo
30Si 41494 37
Apollo40Si 41494
38
Apollo
50Si 41494
39
IMPORTANT
FOR
USEWITHNATURAL
GASONLY.
Read
these
instructions
thoroughly
beforeworking
ontheboiler.
Leave
these
instructions
adjacenttothe
gas
meter.

Section
I
2
3
4
5
6
7
8
9
l0
ll
t2
t3
l4
l5
l6
t7
l8
19
20
2r
22
23
u
LISTOFCONTENTS
Subject Page
Introduction 3
Technical
data 3
Creneral
requirements 4
Delivery 4
Gas
supply 4
Electricity
supply 4
Air supply 4
Fluesyslem 4
Boilerlocation 5
Importantinstallationnoles 5
Boilerdimensions
and
position
of waterand
gas
connections 6
Watersystemschematics 6
Sealed
systemrequirements 7
Instnllation
procedure 8
Commissioning 12
Boilercontrols 13
Finalassemblyand handing
overthe
instqllation 13
Annual
servicing 14
Lightinginstructions 15
Replacement
ofparts 15
Wiring diagrams 20
Fault
finding
guide 23
Explodedview U
Short
list spare
parts 25
If youhave
anyreason !o compliainof anyshortage
of componentslistedin Figs5 or 6, supplyalist of theitem(s)
concerned,
boilermodel,
yourname,
addressandanyinformationwhichmayhelpusavoidfurthererror.
Addressfor return:
Spare
Adminisration ldanager
CurzonComponents
Ltd.
Earlsway
TeamValley TradingEstate
Gateshead,
TyneandWear
NEII OSA
Page 2

1. INTRODUCTION
Thesefanned
draught
room-sealedwallmounted
borlersare
foruseonnatural
gas
only, andare suitableforrear orside
exitflue.
The
Apolloboilersarenmge rated
atthe
followingoutputs:
Apollo
30
Si: 4.4
to8.8
kW (15
000to30000
Btu/h)
Apollo40Si: 8.8toll.7 kW(30 000to40000
Btu/h)
Apollo50Si: I1.7to 14.7
kW(40
000
to50000
Btu/h)
All models
are
factory
s€ttothe
maximumoutpuL
Theboilers
are
designed
foruseonlyonfully pumped open
vented
or sealed
watcr
systems
withanindirecthotwater cylinder.
THEYMUSTNOTBECONNECTED
TO A DIRECTCYLINDER.
2. TECHNICALDATA
For
boilermodelsee
lightinginstruction
label
insidethebottomcoverorthe
data
plate
onthe
inner
case.Forserial
No.seetagon
thebottomof tle innercase
justabove
thecontrolbox(visible
afterremovingthebottom
cover).
Boiler Aoollo 30Si Aoollo
40
Si Apollo 50Si
Burner
type &ay A82,1013Mo.
Furiqas179500-018 bray AEzz+ucr+M
Furigas 175-50G032 Eray482401
4Mor
Furioas175-500-017
Burnerinjector Bray16/800 Bray2811000 Bray16/1400
Pilot
injector Honeywell4500-41
08-005
marked
56/
424
Pilotflame 35to
40
mmlong
Spark
gap 3.0to
4.0
mm
lgnition lntermittent
oilot
Weight
(empty) 27 .3kg(60
lb)
Liftingweight
(installing) 21.8kg
(48
lb)
water
content 0.36
litre
(0.08
gal) 0.€ lire(0.1 gal) 0.50lite
(0.11
gal)
Max.
flow
temperature g20c
Design
temperature
rise goc
Maximum
static
head 30.5
m
(100
ft)
Minimum
static
head 150mm
(6
in)
abovethe
highest
point
in
thesystem
' Headloss 0.38m
(15
in) 0.54
m
QlYzinl 0.71
m
(28
in)
Height 711mm
(28
in)
width 340
mm
(13%
in)
Depth 300
mm
(113/
in)
Clearance
required
for
ServrCrng
I Too 50mm/2in't
I Bottom 90
mm
(3'r'z
in)
, Fronl | 3fn mm r113,.Inl
I Sides | 5
mm
p'.In)
Flue
terminalsize 100 mm
dia.x65
mm
deep
(4
in
dia.
x2'/z
tn
d*9\
Water
connections Compression fittings
toaccept
22mm
coppertubeto
852871
Gasconnection RpV"
' Headloss
given
is
applicableonly
whentheflow
through
the
boiler
is
690
litreVh(2.5
gal/min)
for
the
Apollo
30Si,
910
litres/h
(3.3
gal/min)
for
the
Apollo
40
Si
and
1146litres/h
(4.2
gal/min)
for
the
Apollo
50
Si.
NOMINAL
BOILER
RATINGS
Boiler OuFut Input Burner
setting
pressure
kw Btu/h kw Btu/h mbar inwo
Apollo
30Si 4.4 15
000
8.8 30000 5.8 19
600
11.0 37500 4.1 't.6
14.9 6.0
Apollo
40
Si 8.8 30000
11.7 40
000 11.4 39000
14.7 50000 10.0 4.4
16.5 6.6
Apollo50
Si 11.7 40
000
14.7 50000 14.9 50900
18.3 62500 9.0 3.6
12.2 4.9
Page
3

3. GENERAL
REQUIREMENTS
The
boiler
mustbeinstalledinaccordance
with:
TheGas
Safety
(lnstallation
andUse)
Regulations1984
andthecurrent
issue
of:
theBuildingRegulations,BuildingStandards
(Scotland)
Regulations,Local Building
Regulauons,
ModelandlocalWater
UnderukingByelawsandIEE
WiringRegulations.
Detailedrecommendations
are
stated
inthefollowingBritish
Standards:
85689l:1988,B56798:1987,
855!16:1990,BS5440:l:1990,
8S5440:2:1989
and
B55449:1:1977
.
Note:
Gas
Safety
(Installation
andUse)
Regulations198^l:
Itis
the
law
thatall
gas
appliances
are
installed
bycompetent
persons,
in
accordance
with
theabove
regulations.
Failure
to
install
applnnces
conectlycouldlead
to
prosecution.
Itisinyour
own
interest,
and
that
ofsafetytoensure
that
'Jre
law
is
comnlied
wit}t.
4. DELIYERY
The
unit
is
delivered
intwo
packagcs(
I)the
cased
boilerand
(2)
the
fludterminal
assemblytypeA,B,C,DorEas required.
In
additiona
965mm
(38
in)fiuc extcnsion
isavarlable.
Undernocircumstancesshouldmore
than
two
extension
kits
beused.
A plug-in
progr:rmmer
kitis
alsoavailableto
fit inside
theboilercasing.This
programmer
simplifies
wiring
and
is
suiuble
for
use
with
all
externalcontrolsystems
shown
inthe system
wiring
diagramssupplied
withtheboiler.
A lit from
tie insidekit isavailable
which
enables
the
flue/terminal
assemblyto
be
fitted
frominside
thebuilding.
A Vertexflue kit isavailable which
allowstheboiler!o
be
connecrcdto
avertical
flue
system.
Apump
andby-pass
kitis
available
which
posiitions
the
pump
in
a
readily
accessible
position,
includes
a
built
in
by-pass
which
does
not
rcquireadjusungand
allowsthe
combinedcold
feed
and
vent
tobeconnecteddirectlytothe
boiler.
Thekit includes
anouter
casc
extension
whichincreases
the
boiler
heieht
to861
mm.
5. GAS SUPPLY
Thenatural
gas
requirements
areas
follows:
Apollo30Si:
l.l m3/h(37ft3lh) Apollo40Si:l.4m3lh(51ft3/h) Apollo50Si:1.8
mt/h(62ft3/h)
The
meter
and
supply
pipes
must
becapableofdelivering
this
quantity
ofgas
inaddition
to
the
demand
from
anyother
appliances
in
thc
house.
Thc
complete
installation
mustbe
tested
for
gas
soundnessand
purged
as
describedin 85689l.
6. ELECTRICITYSUPPLY
210V
- 50FIz
via
a
fused
double
pole
switch
with
a
contactseparationofat least
3
mminboth
poles
or
preferably
a
fused
3
pinplug
and
shutteredsocketoutlet
(both
complying
withthe requircments
ofBSl363)
adjacent
tothe
boiler.
Fuse
the
supply
at
3A.Theminimumrequirement
forthe
power
supply
cable
is
that
it should
be
a
PVC
sheathed
flexible
cordat
least
0.75
mm2
(24
x0.2 mm)
(code
designationHO5
VV-ForHO5 VVH2-F)
as
specifiedintable16
of 856500:1984.
All wiring
externalto
the
boiler
shall
comply
with
the
latestIEEWiring
Regulations,
andanylocal
regulations
which
apply.
The
appliance
must
beearthed.
Inthe
evenl.ofan
electrical
fault
after
inslallation
ofthe appliance,
preliminary
elecnicalsystemschecksmust
becarriedouti.e.
Earth
Continuity,Short
Circuit,
Polanty
anC
ResisLancc
to
Eanh.
7. AIRSUPPLY
The
roominwhich
the
boiler
isinsnlled
docs
not
rcquire
a
purposeprovided
air
vent.
If theboiler isinstalledin
acupboardor
compartment,
permanent
air
vents
are
requiredin
0recupboardorcompartrncnt,
oneathigh
level
andoneat
lowlevel,
eitherdircct
totheoutsideairortoaroorn.Bothhighlevel
and
lowlevel
airvents must
communicate
with
the
sameroom
ormust
beon
the
same
walltooutsideair.Boththehighlevel
andlowlevelvent
musteachhave
a
free
area
asstated
below.Thefrec
areaofeach
vent
may
be
halved
if the
ventilation
isprovided
directlyfrom
outside.
Apollo
30Si: 99cm2
(
15
inz) Apollo40 Si: 133 cm2
(20
inz) Apollo
50
Si: I 65cm2
(25
in2)
If the
boiler
isinsulledina
cupboardorcompartment
with
adoor,allow
at
least
100mm
clearancebetween
the
front
ofthe
boiler
andthedoor
for
air
movemenL
E.
FLUESYSTEM
Five
telescopic
flue/terminal
asscmblies
are
availableand
afixedlength, 965mm
(38
in),
extension
kil
Theflue
lengths
are:
SizpA: 123
- 175mm
(43A
-7n)
Siire
B: 17l
-275mm(GA-lUAin)
SizrC: 274
- 478mm
(|Glr
- l8%in)
Siz.cD: 362
-652mm
(l4t/e
-251/tin)
Sze
E: 582
- lW2 mm
(23
-43
in)
Unless
otherwise
specified
theCsize flue/terminalwill be
supplied
with
theboiler.
Thefollowing
method
shouldbe
used
todeterminethe
required
flue/terminalassembly.
RearflueA=C+83mm(3%in) Side flue
A
=
B+
C+ 127
mm
(5
in)
WhereA =requiredflue
length,B= insidewall
to
side
ofboilerandC= finished wall
thickness.
If A isgreater
than
1092
mm
(43
in)oneortwo
extension
kits
maybe
used.
Note:Themaximum
allowable
fluelengthis3022
mm
(119
in).
Poge 4

9. BOILER
LOCATION
Theboiler
isnotsuitable
forexternal
installation.
The
boiler
musrbe
mountedonaflatwallwhich
issufficiently robust
totakethe
weightof theboiler.
The
boiler
is
suitable
forinstallationtoa
combustible
walle.g.
woo<l
cladding,
provided
thattheairlfluetube
assembly
isnotcloser
than
25mm
(l in)
to
combustible
material.
A metalsleeveshouldbc
installed
to
surroundtheairlt'luetube
assemblyto
provide
a
25mm
(l in)
annular
space.
Further
guidance
isgiven
inBS5440:l:1990,sub-clauses3.3and
4.2.5.
If rheboiler istobe
installedinatimber
framedbuilding
itshould befitted
inaccordancewiththeBritishGas
publication
-"Cuide
for
Gas
Installation
inTimber
FramedHousing"
reference
DM2.If indoubt advicc
must
besought
from
the
local
region
ofBritish
GasorfromMyson
Heating.
Theboiler
may
be
installed
in any room,although
particular
attention
isdrawntothc
rcquirements
of thecurrent
IEEWiring
Regulationsand,
in
Scotland,
theelectrical
provisions
ofthe
Building
Standards
applicable
in
Scotland
withrespect
to
the
installation
of thetroiler
in aroom
containing
abath
orshower.
Wherearoom-sealedappliance
isinstalledin
a
roomcontainingabath
orshower,any
electricalswitchorappliancecontrol,utilising
mains
electricity
shouldbesosituated
that
it cannotbetouched byaperson using
thebathorshower.
Where
the
installation
ofthe
boiler
will be inanunusual
position,
special
procedures
maybe
necessary
and
856798
and
855546
give
detailed
guidance
onthisaspecl
Acupboard
orcompartment
usedto
enclosetheboiler
must
bedesigned
andconstructed
specifically
for
this
pupose.
Anexisting
cupboard
or compargnent
maybeused
provided
thatit is modifiedfor thepurpose.
Details
of essential
features
of cupboard/
compartment
design
including
airing
cupboard
installationsare
given
in856798and
B55546
andshouldbecomplied
with.
The
boiler
requires
onlytheclearances
stated
inthetechnicaldata,
page
3,after
installation.If it isfelt
that
extraspace
isrequired
forinstallationanyadjacent
kitchenunitsor fitmentsmayhavetobe
removed.
The
boiler
must
be
installedsothatthe
flue
terminal
is
exposedto
theexternalair.
It isimportantthatthe
position
oftheterminal
allowsthe
free
passage
ofairacross
it atallttmes.
Theminimumacceptable
spacings
from
the
terminaltoobstructions,corners
and
ventilation
openingsare
specificd
in
the
following
table:
Termlnal
posltlon Minimumspacing
Directly
belowanopenable
window,
airventoranyother
ventilationopening 300mm
(12
in)
Below
gutters,
soil
pipes
ordrain
pipes 75mm
(3
rn)
Beloweaves
orabalcony 200mm
(8
in;
Aboveadjacent
ground
orbalcony
level 300
mm
(12
in)
Fromverticalsoil
pipes
ordrain
pipes 75mm (3
in)
Frominlernalor
externalcorn€rs 25mm
(1
in)
Fromasurlace
lacinothelerminal 600mm
(24
in)
From
alerminal
lacingtheterminal 1200mm
(48
in)
Vertically
lromaterminal
onthesame
wall 1500mm
(60
in)
Horizontally
tromalerminalon
lhesamewall 300mm
(12
in)
Adjac€nt
toanop€ning
window 150
mm
(6
in)
From
anopening
inacar
pod
i.e.door
orwindowintothe
house 1200mm
(48
in)
*Ifrhererminal
isfitted
within
850
mm
(34
in)
ofa
plastic
or
paintedgutter/pipe
or
450mm
(18
in)
of
painted
eaves,
analuminium
shieldofar
least750
mm
(30
in)inlength
shouldbe
fittedtotheundersideof the
gutter/pipe
orpainted
surface.
** If theterminal
isfiaed
less
than
2m
(6.6
ft)above abalcony,above
ground
or
abovea
flatroof
to
which
people
havc
access
then
asuitable
terminal
guard
must
be
provided
and
fitted.
A type
Kl protective
guard
isavailble
fromTowerFlue
Components
Ltd.at:
ValeRise,Tonbridge,KentTN9 1TB,Tcl:0732
35
r555.
The
guard
mustbesecurely
fittedtothe
wall
andcentrally
locatedoverthe
flue
terminal.
Refer
tothe
manufacturers
instrucLions.
I().IMPORTANT
INSTALLATION
NOTES
l. TheApolloistobeused
onlyonfullypumped systems,
and
with anindirect
cylinder.
2. {Jnly
high
head
pumpsproducing
atleast
3.35
m(ll f0 head ataflowrate of690
litres/h
(25gaVmin)
forthe Apollo
30Si,910litreJh
(33gaVmin)
forthe Apollo40
Sior 1146litresih
(4.2
gaVmin)
forthe Apollo50Si
must
beused.
3. Connect
the
pump
in the
flowpipe asshovrn
inthe water
systemschematics.
4. Mainselectricity
andthe
pump
must
alwaysbeconnectedtotheboilertoallowthe
pump
overrunto
function.
5. It isimportantthatthe
polarity
ofthe
mains
supply
is
correctandthattheboiler
is
adequatelyearthed.
6. Foropen
vented
systems
acombined
or closecoupled
feed
andventmust beconnectedassho*r in the
watersystem
schematics.
7. Asystem by-pass
is
essential.
Theby-passshould
beof15mm
pipe
and
must
be
asshort
as
possible
acrossthe
22mmflow
and
returnpipes andat
least1.5maway
from
theboiler.Install
theby-passasshown
inthe water
systemschematics
and
adjustasdescribed
in thecommissioning
instructions.
8. Tbe
systemwiring
mustbecompleted
inaccordance with
thediagramssupplied
with
theboiler.
9. When commissioning,
thesystem
mustbe
vented
andthe
pump
running
beforethemainburner islit.
Page5

10.The
systemmust
be
flushed
twice;
initiallycoldwith thepumpremoved
andall valves open,
andthen
afterthefirst
heating.
11.
Where
the
Apollo
replaces
anolder
boilerin anexisting
system,
make
surethecylinderisindirect.
12.In areaswith hardor aggressivewet€rwerecommend
thatFernoxCP3
inhibitorshouldbe
used.Seecommissioning
instructionsfor detailsof use.
13.
Theinner
casc
oftheboiler shouldnotberemoved
duringinstallation.
T1.BOILERDIMENSIONS
ANDPOSITION
OF
WATER
ANDGAS
CONNECTIONS
Refer
toF,g. 1.
Overall
caseddimensions:
Height: 7ll mm
Width: 340
mm
Depth: 300
mm
Clearances
requiredfor servicin
g:
Top: 50
mm
Bottom: 90mm
Front 300mm
Sides: 5mm
See
section9for installation
clearances.
Water connections:
Compression
fittingsaresupplied
for flow andreturn
connections
toaccept22mmcoppertubing
toBS287l.
12.
WATER
SYSTEM
SCHEMATICS
22nn 22mm
Relurn. zJo -^ Flow
. 145 - Fig.I -bE-
a. Fully
pumped
openvented
systemwith combined
cold
feed
and
vent
-s€e
Fig.2.
The
combinedcoldfeed
and
vent
must
rise
fromtheboiler.
Somewater
authorities
require
astopcock
inthe
coldfeed, in which
caseaseparatevent
must
be
connectedas
shown.
b. Lengthof wetanddry ventsfor close
coupled
coldfeed
-see
Fig.3.
The
distance
betweenthe
coldfeed
and
vent
connection
tothe systemmust
not
be
more
than
150
mm.The
point
ofconnection
of
these
pipes
shouldbeas
closetotheboiler
as
practicable.
IAlternative
vent
i arrangement
It
I coldfeedisvalved
Optronal
Zone
Valves
Optrona
.3 pos
t
on
va
ve
See8S5449
clause
24 l
Fig.2
The
by-pass
balancing
valve
should
be
ofatypethatisnon-adjustable
bythehouseholder
andmusrhave
ar
least1.5
mof22mm
pipe
each
sidebetweenit andthe
boiler.
Always
ensurethat
the
pump
has
sufficient
statichead.
Checkthe
pump
manufacturers
minimum
head.
The
flow through
theboilermustnotbe
allowed
ao
fall below690litreVh(2.5 ga[min)fortheApouo30
Si,
910litres/h
(3.3
gaVmin)
forthe Apollo
40
Sior l146litres/h
(4.2
gaVmin)
fortheApollo
50Siwhile
rheburner
isalight
Ensurethat
the
pump
isaccessible
for servicing.
Isolating
valves
must
be
positioned
ascloserorhe
pump
as
possible.
Fitone
ormore
drainingtaps
(BS2879)
toenable
the
water
system
tobe
fully drained.
A - length
of dry venl
B - length
ol waterfilled
vent
C - 150 mD min
T2CDmm
I
Fig. 3
HEATII{G
LOAD VENT
LENGTH
Bu,n A
(mm) (mm)
5C000
40 000
3C000
20 000
.0 000
4n
3(n
z&
140
50
330
m
m
no
no
Page6

13.SEALEDSYSTEM
REQUTREMENTS
Refer
to Frg.4.
a. Theinstallationmust comply
withthe
requirements
of856798 and
BS5449:1.
Maximum
water
temperature
is82oCt 3oC.
b. A safety
valve
settooperat€at3bar
(45
lbf/in2)
shallbe
fittedinthe flowpipe
close!othe
boiler.
Theremust
not
be
any
valves
between
the
safety
valve
andtheboiler.
Thevalve should
be
positioned
onadischarge pipefitted[oprcvent
any
discharge
creating
ahazard
tooccupantsorcausedamage!oelectricalcomponentsand
wiring.
c. A pressuregauge coveringatleast the
range0 m4bar
(0!o60lbf6nz;
shallbe
fittedin thesystem.
d. A diaphragm
type
expansion
vessel,
toBS48
14,
shall
be
connected
atapoint
inthereturn
pipe
close
tothe boiler.
Thevessel
must
bechosentro
suit
the
volume
ofwaterinthesystemandthe charge
pressure
must
notbeless
thanthe
static
head
atthe
point
ofconnection.Further detailscanbeobtainedfrom"Materialand
Installation
Specification
forDomestic
Central
Heating
and
HotWater"published
byBritish Gasand
BS7074:1.
Sizingtable:
Airor NiEogen cfiargeprsssure
(bar) 0.5 1.0
Pre-pressurisation
pressure(bar) None 1.0 None 1.5
Expansionvesselvolume
(lifes) Ax0.07 Ax0.120 Ax
0.088 Ax0.160
A
=
System
volume
(litres)
e. Thehotwater cylindershall
eitherbethe
indirect
coil type
oracylinderfittedwithanimmersion calorifier.
f. Waterlost
fromthe
systemshallbe
replaced
fromamake-up
vessel
and
non-returnvalve,
mountedhigher
thanthetop
ofthe
systemonthe
return
side
of thecylinderorradiators.
Where
accesstoamake-up
vessel
would
bedifficult,make-up canbe
provided
bypre-pressurisation
of thesyste.
g. The
systemmaybefilledfromthemains
via
a
Lemporaryhose
connection
from
adraw-offtap
supplied
from
aservice
pipe
under
mains
pressure,provided
that
this
procedure
is
accepuble
tothe localwater
authority.Thefollowing
fittingsshouldform
a
perrnanentpart
of fre systemand
fittedin theorderstated:
i) astop valve
complying
totle requiremenLs ofBSl0l0:2.
iD atestcock.
iii) an anti-vacuumvalve
ofatyp€approvedbytheNarional
Water
Council.
iv) anon-returnvalve
of anapproved
type.
h. Fill thesystemuntil
the
pressuregauge
registers1.5
bar
(22lbflinz).
Examineforleaks
and
rectify
whcre
neccssary.
Refer
tothe commissioning
instructions,light
the
boilerand
allowthe
systern
toreach ilsmaximumworking
temperature.
Examineforleaks
thenturnoff the boiler.Drainthe
system
whileit isstill hot.Refill, vent
andadjust
the
coldfill pressure to
therequired
value.
The
by-pass
balancingvalve
musthave
at ieast1
5rnof 22mm pipe
eachside
betweenitand
theboiler.
Exoansron
Vessel Optional
Zone
Valve
Optronal
3-position
valve
Fig.4
l5mm
Pressure Balancrng
Gauge -
valve
Page 7

templatesupplied
withtheboiler.
The
overall
size
ofthetemplate
isthe size
oftheboiler
plus
the
minimum
side,topandbottom
clearances.
2. When
youhave
decidedonthe
position
of theboiler
tape
the
template
tothewall,ensuringit islevel
andthecorrect
way
up.
3. Makesure thatthe
position
of theflueterminal
will meet
therequirements
given
in section
9.
4. Markthe
position
of theholefor theflue.
5. Remove thetemplate
(donot
discard
i0 and cuttheI 15mm@th in)diameterholein thewall for the flue/terminal
assembly.
6. Repositionthetemplateonthe
wall,mark,
drill and
plug
the
hvefixingholes
toaccept
215"lg. No.12woodscrews.
7. Makeanote of the
finishedwallthickness, this
isveryimportant
and
isrequiredforsection 14.5when
adjusting
thelengthof
the
flue/terminal
assembly.
8. Remove thetemplateand
position
the
wallmounting
plate
cenrallyoverthehole
inthewall,ensuring
it isleveland
the
right
way
up(studs atthebottom).Secrrrethe
mounting
plate
o thewallwith four21h"lg.No.12woodscrews
(not
supplied).
14.3
Securetheboiler
tothe
wall(rearflue).
Note:The
inner
case
doesnot
need
toberemovedduring
installatron
L Lift the boilerinto
position
and
locate
the
two
holes
inthetop
ofthechassisover
fte studs
onthe
wall
mounting
plate.
Secure
theboiler
tothe
wallmounting
plate
withtwoM6nuts
supplied
with
theboiler.
14.INSTALLATION PROCEDUR.E
14.1Unpacktheboiler
- see
Fig.5.
Note:Donotstandthe boileronitsendas
it will damage
the
gas
valve.
l. Carefullyunpack
theboiler.
Donot
discardthe
packing
untilall
the
items
are
found.
2. Carefullyslideoff the bottom
cover
fromthe boiler.
3. Removetheoutercaseby slackeningthe
botlomfixing screw
and
firmly pullingthe
case
off the
fixing pins.
4. Keeptheoutercase,bottomcoverandinfrll panels
in a safe
place
soas
nottodamagethem beforefitting.
IF REAR EXIT FLUE IS TO BE USED CONTINUE ON
TO SECTION l42.IFSIDEEXITFLT.IE ISTO BEUSED
PROCEED TO SECTION 14A.
14.2Preparethe
wall(rearflue).
L Decideuponthe
position
of the
boiler
usingthe
wallmounting
2. Secure the
bottom
ofthe
boiler
tothe
wallwildl.
a2th" lg.No.l2
woodscrew
(notsupplied)
via theholepreviously
drilledand
plugged.
3. Remove the
fluediverter fromthe
topof theboilertaking
care
nottodamage
the
gasket
4. Connectthe
system
flowand return
pipes
tothetop
compression
unions
(see
watersystem
schematics,section
l2).
5. Refitthefluediverterfacingtotherear.
14.4Unpackthe
flue/terminalassembly
-see
Fig.6.
Carefully
unpack
theflue/terminal
assembly.
Do notdiscard
the
packing
untilallthe
items
are
found.
14.5Adjustthe lengthofthe
flue/terminal
assembly
-see
Fig.
7
(rear
flue).
l. Using themeasurement
notedinsection 14.2
adjustthe
length
of
the
flue/terminal
assemblyso
that
it is:
83mm(3V in)+ finishedwall thickness,
fromthe
back
of the
terminalflange!othe
end
ofthe OUTERair
tubeas
shown
inFig.
1
Note:
Ensure
that
the
seams
inthe
outer
airtubesare
inline.
2. Drillthrough
the
three
pilot
holes,
shown
inFig.7,with
a
2.8
mmdrill and securethetwo nrbesogetherusingthethree
No.8x l0lg. screws suppliedwiththeflue/terminal
assembly.
Note:When
drillingthroughtheouterairtube
take
care
not
todamagethe
innerfluetube
withthe
drill.
3. Seal
thecentre
joint with thetape
supplied
with theflue/
terminal
assembly.
t!
mountrng
plate
T??TTT??
No 8 x 12 19 scraaa 8 off
6@
M6 nuts 2off
Flnd these
parlsin the pack.
Fis.5
cover
Clamping
ring2 off
gggg
M4 ' 1619
screws
4 off llll
AAAg
No.8 x 1" lg
sranress
screws 4 of{
I roll oi sealing tape
o
'O'ring
Outer seaftng
plate
AAJ
No8' lOlg
screws
3 of{
Flnd there parts in lhe pack.
Fig.6
Outer
wall
plate
Flue./lerminalass€mbl!
Seal
this
loint
wtth tape
supplied
Keeoseams
Finished
wallthickness
Inlrne
* 83
mm(3%
in)
---
Prlot
notes
t3off)
F+
Fig. 7
Page I

14.6
Fitthe
flue/terminal
ess€mbly
-s€eFig.t (rearflue).
Note:
If the
wallistobe made
good
upo the terminal,
the
outerwallplate
need
notbeused.
1. Fit theouter wallplate overthe flue/terminal
assembly.
2. Fit the'O' ring in position
overtheouter air tube
against
theflared
section.
3. Fromoutside
thebuildinginserttheflue/terminal assemblyinto the
wall.Ensure
thatthe
slotsin the end
of theterminalare
vertical.
4. Push
the
flue/terminal
assemblylowardstheboiler
and
engage
thetube
intothe fluediverter
ontopof the boiler,
ensuringthatthe
innerflue
tubeslides
INTO the inner
tube
of the
diverterandtheouter
airtube
slides
intothe
diverter. Fig.
t
Fig.9
,!?' '.u.r'r€
Fig.I0
Check
thatthe'O' ringisontheboiler'sideof theflaredsection.
Pushfully home
untiltheflared endof theouler
tube
isincontactwith the fluediverter.
14.7
Connect
thefluetotheboiler
-seeFig.
9(rearflue).
l. Fitthetwo halves
ofthe
clamping
ring
overtheair
tube
asshowninFig.
9.
Ensure
thatthe
flatsideisagainstthe
wallmounting
plate,
and
the
recessed
sideagainst
theflaredpartof theair tube.
2. Securetheclamping ring
tothe
fluediverter
usingthe
fourM4screws
supplied
(use
the
threaded
holesin theclamping ring).
3. Tighten thescrewstoseal
the
flueassembly.
4. Proceed
losection14.14.
14.E
Preparethewall-seeFig.10
(side
flue).
l. Decideupon
the
position
oftheboiler
using
thewallmounting
template
supplied
with theboiler.Theoverallsizeof thetemplateis sizeof theboilerplusthe
minimumside,
topand
bottom
clearances.
Note
that
the
maximum
distance
(using
thelongestflue/terminal
assemblyand
two965mm
(38
in)flue
extensions)from
the
side
ofthewhite
casetotheOUTSIDE
ofthe
wallis2895
mm
(114
in).
2. Tape
the
wall mounting
templatetothe
wall,ensuringit islevel
andthecorrect
way
up.
3. Continue thered
line,
on
thetemplate,
horizontally
across
the
walluntil
itreaches
the
side
wall.
4. Tape
the
sidefluetemplate,
supplied
with
theboiler,
tothesidewallso
that
it is
inLhecornerandthat
theline
just
drawn
lines
up
with
the
red
line
on
thetemplate.
5. Makesurethat
the
posirion
ofthe
flue
terminal
nill meet
tie requiremcns
given
insection
9.
6. Mark the
positions
of the
fourwallmounring
plate
fixingscre
*s andthelo*er
fixingscrew.
7. Drillandplugthefivefixingholes!oaccept2th"
lg.No.l2
*mdscre*s.
\{ark
r}r
position
oftheholeinthe
side
wallforthe flue/terminal
assembly.
8. Cutthe ll5 mm (4rhin)diameterholein theside wall for rhe
flueAcrmrnal
assembly.
9. Makeanote
oftle finished
wallthickness
andthe
distance
from
theside
*all to
the
side
ofthewhitecase
as
shownon
thetemplate.These
measurements
are
ver)'
important
andare
requiredinsection 14.10when
adjustingthe
length
of tlre flue/termrnal
asse
mbly.
10.
Removethe
templates
and
place
thewallmounting
plate
inposition
ontlrewall
ensuringrrrsle
vel
andthe
rightway
up
(studs
atthe
botrom).
Secure
themounting
plate
!o
thewallwithfour21h"lg.No.l2woodscre*
s
(
nor
supplied).
14.9
Securetheboilertothe
wall(side flue).
Note:The inner
casedoes
notneed
toberemoved duringinsnllation.
I. Lift theboilerinto
position
and
locate
thewo holes inthetop
offte chassisoverthe
studsonthe
wall
mounting
plate.
Secure
the
boilertothe
wall mounting
plate
with nvoM6 nuts
suppliedwith the
boiler.
2. Secure
thebouom
ofthe boilerto
the
wallwith
a2l5" lg.No.12woodscrew
(not
supplied)
i'ia
rlrehole
previously
drilled
and
plugged.
3. Removethefluediverter fromthe topof theboiler
takingcare
nottodamage
the
gaskcr-
4. Connect
the
system
flowand return
pipes
tothe
topcompression
unions
(se€
water
systemschematics,
sectionl2).
5. Refitthe fluediverter facing
leftorrightasdetermined
bythefluedirection.
6. Unpack theflue/terminal
assemblyasdescribedin section 14.4.
Page 9

14.10Adjustthelength
ofthe
flue/terminal
assembly
-see
Fig.11
(side
flue).
l. Usingthem@surementsnotedin section 14.8,
adjustthe
lengthof the
flue/terminalassemblyso
that
it is:
127mm
(5in)+A + B,fromtheback
of theterminalflange
totheend of the OUTER
airtubeasshown
in Fig. Il.
WhereA isthe
finishedwallthicknessand B isthedistance
between
thesidewall andthesideof the
white
case.
Note:
Ensurethattheseams
inthe
outerairtubesare
inline.
2. Drill throughthethree
pilotholes,
shown
inFig. I l, witha
2.8
mm
drilland
securethe
two
tubes
togetherusingthethree
No.8x l0lg. screwssup'plied with
the
fluelterminal
assernbly.
Note:
Whendrillingthroughtheouterairtubetakecarenot
todamageiheinner fluetube
with thedrill.
3. Sealthecenre
jointwiththetape
supplied
with
theflue/terminal
assembly.
l4.ll Flue
extension
-see
Fig.12
(side
flue).
Theflue
extension
kitallowsthestandard flue/terminal
assembly
tobe extendedby965
mm(38in).
A maximum
of twoflueextension maybeused,
if required.
l. If theflueextensionkit isused,connectthe
plain
endofthe
extensionto theswagedend
of thesondard flue/terminal
assembly.Ensure
thatthe
innerflue
tubeof
thestandafiflue/
terminal
fis INSIDEthe
innerfluetubeoftheextensionand
theouteraL tubefits OVERtheair tubeof theextension.
Pushfullyhome.
Note:
Ensurethattheseams
intheouter
airtubes
are
inline.
Seal
this
loint
with tapesupplied..
Extension Keeps
seamsin line Standard
flueltermrnal
assemblv
Fig. 12
2. Drill threeequally
spaced
holes
usinga2.8
mmdrill inthe
position
shown
inFig. 12,
through
boththestandard
fluelterminal
andtheextensiontubesleeve.Serurethetwo
&bes
togetherusing
thethree
No.8x l0lg. screws
suppliedwiththeflueextension.
Note:
Whendrillingthroughtheouterairtubetakecare
not
to
damage
the
inner
flue
tube
withtlredrill.
3. Sealthe
lrints withthetape
supplied
withthe
flueextension.
4. AdjusttheOVERALL length
asdescribed
insection 14.10.
Secureand
seal
the
joins.
14.12
Fittheflue/terminal
pssembly-s€€
Fig.13
(side
flue).
Note:
If the wall istobemade
good
upto the
terminal,tlreouter
wall
plate
neednotbeus€d.
l. Fit theouter wallplate
overthe
flue/terminal
assembly.
2. Fitthe
'O' ringinposition
over
theouterairtube
against
theflared
section.
3. From outsidethebuilding
insert
the
flue/terminal
assembly
into
the
wall.Ensure
that
theslos in theendof theterminal
are
vertical.
4. Pushtheflue/terminalassemblytowardsthe
boilerandengagethe
tube
into
theflue
diverter
ontopofthe
boiler,
ensuring
thatthe
inner
fluetube
slidesINTOthe inner
tube
ofthe
diverter
andtheouter
air
tubeslides
intothe diverter.
Checkthatthe
'O' ringisonthe
boilersideof theflaredsection.
Push
fully home
untilthe
flared
endof the
outertube
isincontact with thefluediverter.
14.13
Connect
the
fluetotheboiler
- see
Fig.14
(side
flue).
l. FitthetwohalvesoftheclampingringovertheairtubeasshowninFig.14.Ensure
thatthe
flatside
isfacing
away
fromthe
boiler,andthe
recessed
side
isagainstthe
flared
part
of theairtube.
2. Securetheclamping ring
to
theflue
diverterusingthe
fourM4screwssupplied
(use
thethreaded
holes
in theclampingring).
3. Tighten thescrews
toseal theflueassembly.
4. Make
good
the
gap
onthe
inside
wallaroundthe fluetube.
Fig.14
Sealthrs;oint
wrlh tape
supplied , Pilor holes (3 off)
Keep seams rn lrne
+--
Finished wall thickness +8+ 127mm (5 tn)
Fig.11
Page
I0