Trianco EuroStar Band A User manual

Trianco EuroStar Band A
15/20, 20/26 & 29/36kW
For Balanced or Conventional Flue
OPERATION, INSTALLATION,
COMMISSIONING & SERVICING
INSTRUCTIONS
Please read these instructions carefully before installing,
commissioning and using this appliance.
To be retained by the householder.

HEALTH AND SAFETY
INFORMATION FOR THE USER, INSTALLER AND SERVICE ENGINEER
Under the Consumer Protection Act 1987 and the Health and Safety at Work Act 1974, it is a
requirement to provide information on substances hazardous to health (COSHH Regulations 1998).
TR Engineering takes every reasonable care to ensure that its products are designed and constructed to
meet these safety requirements when the products are properly installed and used. To fulfil the
requirements, products are comprehensively tested and examined before despatch.
When working on the appliance, it is the responsibility of the user or engineer to ensure that personal
protective clothing or equipment appropriate to parts that could be considered hazardous or harmful is
worn.
This appliance may contain some of the items below:
Insulation and Seals
Glass rope, mineral wool, insulation pads, ceramic fibre and glass insulation.
When handling, avoid inhalation and contact with eyes. These may be harmful and cause irritation to the
skin, eyes, nose or throat. Use disposable gloves, facemasks and eye protection.
After handling, wash hands and other exposed areas. When disposing of materials, limit dust and the risk
of inhalation by using a water spray. Ensure materials are securely wrapped.
Seek urgent medical attention if inhaled or ingested. Exposure to eyes and skin should be followed by
immediate cleansing of the affected areas and medical attention if necessary.
Glues, Sealants and Paints
The glues, sealants and paints used present no known hazards when the appliance is used in the
manner for which it is intended.
Mineral Oils
The appliance is designed to run on 28 sec. Kerosene class C2. The effects of mineral oils on the skin
will vary depending on the length of exposure.
Avoid any skin contact with oil or clothing contaminated with oil. Kerosene will remove the protective
grease normally present on the surface of the skin, rendering it dry, liable to cracking and more prone to
damage caused by cuts and abrasions. Seek immediate medical attention for any rash, wart or sore that
develops on any part of the body.
Barrier cream that contains lanolin, such as Rosalex Antisolv is recommended together with a strict
regime of personal cleaning.
Do not breathe oil vapours. Do not fire the burner in the open (i.e. out of the boiler), as a misfire will
produce unburned oil vapours. Under no circumstances should mineral oils be taken internally.

CONTENTS Page
How to use the boiler 4
Boiler & system control 4/5
Oil 5
Simple fault finding 5
Commissioning & servicing 5
After sales service 6
Installation notes 7
Technical information 8
Dimensions & connections 8
Technical specifications 9
Installation 10
Regulations / Health & Safety 10
Siting 10
Ventilation 10/11
System design 12
Electrical supply & wiring diagram 12
Condensing system 13
Oil 14
Storage & protection 14
Supply 14/15
Flue systems 16
Conventional chimneys 16
Balanced flues 17-26
Commissioning 27
Procedure 27
Handing over 27
Servicing 27
Procedure 27/28
Baffle configurations 29/30
Fault finding 31/32
Spares 33
Spares list 33
Assembly drawing 34

INTRODUCTION
The EuroStar will provide domestic hot water and
central heating. It is supplied with adjustable
boiler control and manual-reset high limit
thermostats. The system requires little more
attention than the setting of the boiler thermostat
and any system controls—such as a room
thermostat or programmer.
The boiler has been designed and constructed to
give years of trouble-free service, and these
instructions are provided to assist you in obtaining
the best performance with the least trouble and
cost.
To help TR Engineering provide the highest levels
of customer service, it is important that the
registration card is completed in full and returned.
BOILER CONTROL
Starting the boiler
Ensure the system is full of water, that there is
sufficient oil in the storage tank and that all
isolation valves are fully open.
Check that the programmer is on and that the
room thermostat is calling for heat.
Set the boiler thermostat (fig 1) to the desired
water temperature.
Switch on the electrical supply to the boiler. After a
few seconds, the burner should light.
Set the programmer to activate the boiler for
central heating and domestic hot water as required.
The boiler should now operate automatically, switching
on and off according to demand.
Boiler control thermostat
The boiler control thermostat (fig 1) allows selection of
water temperatures at five positions between 55°C and
82°C. Where a cylinder thermostat is also fitted to the
system, ensure that the boiler thermostat is set above
or equal to the highest setting.
The boiler may be switched off by turning the boiler
thermostat fully anti-clockwise. If the boiler is to be
inactive for a long period, switch off the mains
supply and/or set the programmer to the off
position.
High-limit thermostat
The high-limit thermostat is factory set and cannot be
adjusted. Should the water temperature rise to 110°C,
the limit thermostat will shut the appliance down.
The limit thermostat reset button is located on the rear
of the boiler control box (fig 1). The limit thermostat can
only be reset when the water temperature in the boiler
has dropped by at least 20°C.
If the limit thermostat operates frequently, consult a
service engineer, as there may be a fault in the system.
Burner lock-out
If the burner fails to light, it will go into a lockout mode,
indicated by illumination of the reset button on the
burner (fig 2). Press the button. If a lockout reoccurs,
wait for one minute before pressing the button again.
If the problem persists, follow the faultfinding guide on
page 5 before switching off the electrical supply to the
boiler and contacting a service engineer.
DO NOT reset the burner more than twice in one failure
period, as repeated attempts to do so may cause
permanent damage to the internal components.
FIG. 1
FIG. 2

SYSTEM CONTROLS
Room thermostat
To prevent the boiler switching off before the
room has reached the required temperature, the
room thermostat should not be positioned near a
heat source, such as a radiator, or be exposed to
direct sunlight. Follow the manufacturer's
guidance for optimum siting positions.
Programmer
When choosing the operating times for the boiler,
remember that the central heating system may
take up to one hour before becoming effective,
and will usually remain warm for up to half an
hour after the boiler has switched off. As such, it
may be possible to switch the programmer off
early as an economy measure.
Frost protection
If the boiler is to be switched off during very cold
weather, or is located in a boiler room external to
the property that is being heated, the water may
be in danger of freezing. This can be prevented
by fitting the boiler with a frost thermostat that will
cause the boiler to light if the temperature nearby
drops too low.
Where the system is not protected, the boiler can
be left on and the room thermostat set to a low
position (e.g. 5°C).
System shut-down
If the system is off for long periods during very
cold weather, it may be advisable to completely
drain the system. Be aware that too-frequent
draining should be avoided—especially in hard
water areas—as this could lead to scale build-up
in the boiler waterways.
If the boiler is to be shut down for the summer
months, it is advisable to have it serviced as soon
as possible, to minimise the risk of corrosion to
the heating surfaces.
OIL
The only heating oil suitable for use on this boiler
is kerosene class C2. DO NOT use any other
heating oil. Failure to use the correct oil will
invalidate the warranty.
Ensure the oil storage tank is topped up regularly;
do not wait until the tank is empty, as sludge and
water could be drawn into the supply pipe,
adversely affecting the operation of the burner
and potentially reducing the life expectancy of the
oil pump.
After an oil delivery, allow half an hour for the oil
to settle in the tank before using the boiler. Sludge
and water caused by the build-up of condensation
should be drawn off at the drain cock on the tank
once per year.
FAULT-FINDING
If the boiler fails to start, carry out the following
checks before contacting your service engineer:
Check for failure in the electrical supply
Check for a blown fuse. If the fuse has blown
and the replacement also blows, switch off the
mains electrical supply to the boiler and
contact your service engineer.
Check that there is oil in the tank and that all
isolation valves are fully open.
Check for burner lockout (page 4).
Check that the boiler thermostat is switched
on and that the programmer and room
thermostat are calling for heat.
Check that the high-limit thermostat has not
operated (page 4).
Note: if the boiler has been shut down due to a
failure of the electrical supply, it may be
necessary to reset the programmer to the
correct time, unless the device has an in-
built power reserve.
See pages 30–31 for comprehensive faultfinding
guidance for engineers.
COMMISSIONING & SERVICING
To ensure the continued efficient and reliable
operation of the boiler, it is essential that the
burner be commissioned immediately after
installation and prior to first use. The boiler
requires an annual service thereafter.
Important notes
It is a requirement of the guarantee and any
extended warranty that the boiler is commissioned
and receives an annual service. It is the
responsibility of the installation engineer to ensure
commissioning is carried out.
Commissioning and servicing must be performed
by a qualified engineer, preferably OFTEC trained
and registered. Electrical safety checks should be
carried out by a qualified electrical engineer.
It is a requirement of the guarantee and any
extended warranty that the system is flushed out
and protected with an appropriate corrosion
inhibitor, e.g. Fernox.

AFTER SALES SERVICE INFORMATION
A qualified field service engineer is available to
attend a breakdown occurring during the boiler's
guarantee period.
The boiler must be made available for attendance
during normal working hours, Monday to Friday.
Please note that upon attendance by a TR
Engineering engineer, a charge will be made
where:
The engineer finds no fault with the boiler.
The cause of the breakdown is due to parts of
the system not manufactured or supplied by
TR Engineering.
The cause of the breakdown is due to
incorrectly fitted spare parts, or third-party
spares not designed for use with the boiler.
The boiler has not been installed in
accordance with these instructions.
The boiler has not been commissioned by a
qualified engineer.
The boiler has not been serviced annually
since installation.
The breakdown occurs outside the guarantee
period.
The appliance has not been maintained
correctly.
The breakdown occurs due to use of the
boiler not sanctioned by these instructions.
The breakdown occurs as a result of work on
the appliance by an unauthorised third party.
Important:
Invoices for attendance and repair work by
any third party will not be accepted unless
authorised in advance by TR Engineering Ltd.
Technical Assistance
A team of trained technical advisors is available to
discuss any problem with the appliance. In many
cases, the problem may be solved over the
telephone, eliminating the need for an engineer's
visit.
How to report a fault
Step 1: Contact your installation or service
engineer, who should thoroughly check
their own recent work before the
attendance of a TR Engineering engineer
is requested.
Step 2: Contact the TR Engineering service line
for assistance.
Before making contact, please have the following
information ready:
The appliance serial number or your unique
customer identification number (issued upon
registration of the appliance with TR
Engineering).
A description of the fault and any unusual
behaviour by the boiler before the failure
occurred.
The installation and commissioning dates,
and the details of any annual services.
Important notes
As a replaceable item, burner nozzles are only
guaranteed until the first service.
Over 50% of all service calls are found to have no
appliance fault.
Appliance Serial No.: ___________________
Cust. ID No.: ______________________
Installation Date: ____/____/____
Service Centre and Technical Support
Tel: [phone] Fax: [phone]
Hours of Business
Monday –Thursday: 8:30am –17:00pm
Friday: 8:30am –14:30pm

INSTALLATION
The Contractor Plus has been designed to
conform to European Directives/Standards BED
92/42/EEC, LVD 73/23/EEC, EMC 89/336/EEC.
The boiler design incorporates a secondary
stainless steel heat exchanger to recover heat
from the flue gases that is normally lost in
conventional oil-fired boilers.
The matched pressure-jet burner is quiet in
operation and ensures clean and efficient
combustion, with low NOx emissions.
The boiler is suitable for all-normal open-vented
central heating and indirect hot water systems.
With the appropriate safety equipment, the boiler
can also be used with sealed systems up to a
working pressure of 3 bar.
Two flow and return sockets are provided to
facilitate connections to the heating and hot water
circuits.
Due to the high efficiency of the boiler, and to
comply with the Building Regulations (Part L), it
must be fitted to fully pumped systems only.
The front-mounted access cover permits easy
access for removal of the baffles and cleaning of
the heating surfaces. If the boiler is installed
under a kitchen worktop, this should be made
removable to give easier access to the flue gas
sample point and condensate cleaning port (see
page 28).
The only heating oil suitable for use on this boiler
is kerosene class C2. DO NOT use any other
heating oil or a mixture of heating oils. Failure to
use the correct oil will invalidate the warranty.
Flues
The boiler is supplied suitably equipped for
connection to a conventional chimney, but when
installed with a TR Engineering balanced flue kit it
becomes a room-sealed appliance. These kits
allow the boiler to be installed in a wide variety of
site conditions. The balanced flue is available in
horizontal, high-level horizontal and vertical
formats. All flues are suitable for installation in
garages, and conform to the requirements of
OFSA100. See pages 17–26 for balanced flue
options.
Flushing and water treatment
The performance of the boiler could be impaired
by system debris or the effects of corrosion. New
systems must be thoroughly flushed to remove
metal filings, solder, machining oils and any other
corrosive fluxes or greases before connecting the
boiler.
When fitting the boiler to an existing system, clean
the system by using an appropriate flushing and
descaling agent. Refer to BS 7593 (1992) for
guidance.
The system must be protected with a corrosion
inhibitor. Flushing agents and corrosion inhibitors
must be suitable for use with mild steel boilers
and comply with BS 7593 requirements. It is
strongly recommended that a suitable anti-freeze
product is applied to the system after flushing.
Failure to flush the system and add a corrosion
inhibitor may reduce the lifespan of the boiler and
will invalidate the guarantee and any extended
warranty.
Failure to fit the boiler to a fully pumped system
will impede its correct operation and invalidate the
guarantee and any extended warranty.
The boiler must not be run without water in the
system.
It is the installation engineer's responsibility to
ensure that the boiler's output matches the heat
requirements of the system. Failure to do so may
impede the boiler's correct operation and
invalidate its guarantee and any extended
warranty.

FIG. 3
FIG. 4
15–26
29–36
A
460
460
B
854
895
C
597
672
D
355
404
E
603
660
F
693
761
G
743
821
H
16
16
J
60
60
K
37
37
L
197
198
M
85
85
N
71
71
P
231
231

TECHNICAL SPECIFICATION
15–20kW
20–26kW
29–36kW
SEDBUK Efficiency Rating
A
Input1
18.8kW (64,146 Btu/h)
25.0kW (85,300 Btu/h)
34.3kW (116,929 Btu/h)
Output1
17.9kW (61,748 Btu/h)
23.0kW (78,476 Btu/h)
33.0kW (112,596 Btu/h)
Weight
130 kg
160 kg
Water Content
26 litres
32 litres
Flow and Return Connections
22mm compression
Conventional Flue Socket
4” (100mm)
Maximum Operating Pressure
3 bar (43.5 psi)
Test Pressure
4.5 bar (65.3 psi)
Starting Current
3.5 amp
Running Current
0.77 amp
Control Thermostat
Adjustable up to 82°C
Limit Thermostat
Factory-set at 110°C
Fuel
Kerosene 28s C2 to BS 2869
Casing Finish
White
Thermal Insulation
Boiler shell insulated with glass fibre
Electrical Supply
230/280V –50Hz fused at 5 amp
Optional Extras
TR Engineering balanced flue kits (see page 16 onwards)
Factory Setting

INSTALLATION (cont.)
Regulations
Installation of the boiler must comply with the following:
BS 5410 Part 1: Code of Practise for Oil-firing.
BS 5449: Forced Circulation Hot Water Central
Heating Systems.
Building Regulations Part J (England and Wales),
Part F section 111 (Scotland), Part L.
Control of Pollution (Oil) Regulations.
IEE Regulations (BS 7671).
Local Water Undertakings Bylaws.
OFTEC Requirements for Oil-fired Boilers and Oil
Storage Tanks, OFST 100 & OFST 200.
Health and Safety at Work Act
The installation engineer should be aware of his or her
responsibilities under the Act and provide—where
necessary—appropriate protection for all persons
carrying out the installation.
In the interests of safety, the boiler must only be
installed, commissioned and serviced by a qualified
engineer, preferably OFTEC-trained and registered. A
guide to safe working practices for oil engineers is
available from OFTEC.
Electrical work should be carried out in accordance with
BS 7671 by a qualified electrical engineer.
Pluming
Due to the condensing nature of the boiler, a plume of
water vapour will occasionally discharge from the flue;
this should be taken into account when siting the
terminal. Refer to pages 16–17 for details.
Clearance and service access
Ensure adequate clearance is allowed for making the
water and flue connections (fig 3). If the boiler is
installed under a kitchen worktop, this should be made
removable to give access to the flue gas sample point
and condensate cleaning port (page 28). About 750mm
should be left at the front of the boiler for service
access.
Hearth
The boiler must be installed on a level, non-combustible
base that is capable of supporting the installed weight
of the boiler, including its water content.
Sound levels
While the low sound level of the boiler makes it suitable
for utility room or kitchen installation, the following
factors should be taken into consideration before
installation:
Some people are more sensitive to noise levels
than others—discuss with the householder.
Small rooms tend to amplify noise, particularly if
the room's construction is hollow or the surface
tiled.
A chimney passing through a bedroom will transmit
noise.
Low-level flue terminals produce some exhaust
noise, so care should be taken when siting
adjacent to neighbouring properties, patios and
play areas.
Combustion and ventilation air
The provision of an adequate combustion air supply is
essential for the safe and efficient operation of the
boiler. The air opening should be positioned to cause
the least possible nuisance to the end user, and located
in a place that will reduce its likelihood of being
accidentally blocked.
As per BS 5410 Part 1 (Code of Practice for Oil), for
conventionally-flued boilers a permanent opening of
550mm2per kW of boiler rated output above 5kW is
required (see table below and fig 5).
Although no combustion air openings are required for
balanced-flued boilers, ventilation is required to prevent
overheating of the boiler controls if installed in a
compartment or other confined space (see fig 6).
If the boiler room has an extractor fan, the combustion
performance of the boiler must not be affected when
the fan is running and all doors and windows are
closed. A flue gas analysis on the smoke and CO2
levels should be carried out to prove that combustion is
taking place satisfactorily.
Output (kW)
Detail 'A' (fig 5 & fig 6)
15
55cm2
17.5
69cm2
20
83cm2
23
99cm2
26
115cm2
29
132cm2
33
160cm2
36
171cm2

FIG. 5 Conventional Flue
FIG. 6 Balanced Flue

Heating and hot water systems
The heating system should be installed in accordance
with current HVCA Codes of Practice and BS 5449
Part 1 (Forced Circulation Hot Water Central Heating
Systems).
The water flow connection can be made to one of the
two tappings on the left or right side of the boiler. The
return connection can be made to one of the tappings
on the secondary heat exchanger. See fig 3 for details.
A drain-off cock should be fitted at the lowest part of the
system. Where the boiler is also used for providing
domestic hot water, an indirect cylinder to BS 1556
Part 1 must be used.
Flush the system to remove any residue before
installing the circulating pump. Ensure all unused
tappings are plugged before filling the system.
To achieve maximum system efficiency, the heating
system should be designed to ensure a boiler flow
temperature of between 55°C and 70°C, and a flow
differential temperature of between 20°C and 30°C.
Electrical supply
All electrical wiring must be carried out by a qualified
electrician in accordance with current IEE Regulations
and any local regulations that apply.
The boiler must be earthed and the supply cables must
be longer than the current-carrying conductor cables
(i.e. live and neutral supply cables). The minimum
requirement for the power supply is PVC sheathed
flexible cord, 0.75mm² (24x0.2mm, code designation
H05 VV-F or H05 VVH2-F), as specified in table 16 of
BS 6500.
The 230V, 50Hz electrical supply must be fused via a
double-pole switch—with contact separation of at least
3mm in both sides, and via a shuttered socket adjacent
to the boiler (both devices must meet the requirements
of BS 1363).
All external cables entering the control box must be
secured in position through use of the strain-relief
bushes (supplied, see fig 7).
In certain areas, there may be a known risk of high and
low voltage fluctuations; though use of a voltage-
sensitive device, the burner should be prevented from
starting if the voltage drops or rises to a level sufficient
to endanger the installation.
FIG. 7

Condensate drain connections
The boiler comes equipped with its own condensate
trap in the form of a 22mm 'U'-shaped pipe connected
to the secondary heat exchanger. The pipe can be run
to the left or right of the boiler; for ease of installation, it
should be fitted before the boiler is positioned.
To install the condensate pipe, remove the boiler back
casing. After deciding the direction in which to run the
pipe, feed the long end through the side casing from
inside. Attach the short end (with the connecting nut) to
the rear underside of the secondary heat exchanger,
ensuring a watertight seal is made (fig 8).
After the boiler has been positioned, the trap should be
connected to a 22mm plastic or stainless steel pipe (not
supplied) to take the excess condensate to a drain or
soakaway (where possible, an external drain should be
used). The drainpipe should be installed to allow the
condensate to drain naturally from the boiler, on a
minimum fall of 1:20 (fig 9). Insulate any external
pipework to prevent the condensate from freezing. DO
NOT use copper pipework for the condensate drain.
If the boiler is installed below ground level, and there
are no internal drains, a condensate pump can be fitted.
Refer to manufacturers' instructions for best practise.
The trap must be filled with water to create a seal that
stops the escape of flue gases through the drainage
pipework. To fill the trap, remove the cleaning port plug
from the top of the boiler and pour a small amount of
water inside. The trap will have sufficient water when
water emerges from the drainage pipe.
DO NOT fire the boiler without first ensuring the
condensate trap is filled with water. Failure to do so
may result in damage to the pipework, allowing flue
gases to escape. Any damage caused as a result of not
filling the trap will not be covered by the guarantee.
Examine the pipework and rectify any leaks. The trap
should be inspected at regular intervals to ensure
correct operation, and it should be checked as part of
the annual service schedule.
FIG. 8
FIG. 9

OIL
The burner will only run on kerosene class C2 to
BS 2869. Failure to use the correct oil—or use of a
heating oil mixture—will invalidate the warranty.
Storage tank
The oil storage tank should be large enough to allow for
an economic delivery schedule. It should be located in
an unobtrusive position that nevertheless provides easy
access for deliveries and pays regard to safety issues,
maintenance and the head of oil required.
The tank should be fitted with weather-protected fill and
vent connections, a drain-off and an oil level indicator.
Plastic or Steel tanks may be used, and must comply
with the requirements of BS 799 Part 5 (Specification
for Oil Storage Tanks). Steel tanks must be mounted on
brick or block piers, with a waterproof membrane fitted
between the piers and tank.
Fire protection
While it highly unlikely that a fire could start from a
domestic oil tank, protection is required from a fire that
may originate elsewhere. The tank should be at least
1.8 metres from any building and 750mm from a site
boundary. Where it is not feasible to adhere to these
limits, the building wall must not have any openings
other than those required for ventilation, and the wall
must have a fire resistance of half an hour extending at
least 1.8 metres from any part of the tank.
Alternatively, a non-combustible radiation barrier—
meeting the requirements of BS 5410 Part 1—can be
fitted. This applies to tanks of up to 3,500 litres
capacity.
Fire protection must be provided to the eaves if less
than 1.8 metres from the top of the tank. Cladding must
extend at least 300 beyond the tank—which must be
mounted on a non-combustible base.
Pollution protection
The tank must be bunded (double-walled) if:
The tank is less than 10 metres from a stream.
The tank is less than 50 metres from a well, spring,
or other source of drinking water.
The tank cannot be seen from the point of delivery.
There is a risk of oil reaching a manhole cover or
drain in the event of a leak.
The tank capacity exceeds 2,500 litres.
Supply
A long-life flexible oil hose is supplied with the boiler. A
filter and shut-off valve are also required. These should
be fitted in the positions shown on figs 10, 11 and 12.
All oil line joints must be completely sealed and the total
pipe run should be thoroughly flushed before
connection is made to the burner. DO NOT use
soldered joints in the oil line.
A remote-operated fire valve must be fitted in the oil
supply line, externally to the premises, with the sensing
phial located at a point within the boiler casings above
the burner.
Single-pipe oil supplies (fig 10)
Where the lowermost part of the tank is above the level
of the oil pump on the burner, a single-pipe gravity
system can be used. The supply pipe should be
connected to the suction port on the burner pump via
the flexible hose (supplied).
Two-pipe oil supplies (fig 11)
Where the lowermost part of the tank is below the level
of the burner, a two-pipe suction lift is necessary. A
second flexible hose will be required, and the oil pump
must first be converted for use. See the burner leaflet
for details.
A spring-loaded non-return valve must be fitted in the
suction line to prevent the back-flow of oil when the
burner is not running. No valves are to be fitted to the
return line.
The pump suction must not exceed 0.4 bar, as
dissolved gas may be released from the oil, affecting
combustion. The return pipe must end at the same level
as the suction outlet to prevent loss of prime. The tank
outlet should be approximately 75mm above the bottom
of the tank to prevent the drawing off of sediment and
water when the oil begins to run low.
Single pipe oil supplies with a de-aerator (fig 12)
Where a two-pipe suction lift is required, but it is not
feasible to fit a return pipe, an oil de-aerator can be
used. The burner should be piped—and the pump
converted—as for a two-pipe system, up to the de-
aerator, at which point a single pipe can be taken to the
storage tank. The de-aerator should be fitted as close
to the boiler as possible—though externally to the
premises—at a height no lower than the oil pump.
A non-return valve is not required.

FIG. 12
FIG. 11
Lift (H)
0
0.5
1.0
1.5
2.0
3.0
3.5
8mm ID Supply
Maximum Run
(Metres)
35
30
25
20
15
8
6
10mm ID Supply
100
100
100
90
70
30
20
FIG. 10
Lift (H)
0.5
1.0
1.5
2.0
8mm ID Supply
Maximum Run
(Metres)
10
20
40
60
10mm ID Supply
20
40
80
100

FLUE SYSTEMS
To evacuate the products of combustion safely and
thoroughly, the boiler must have an efficient flue
system. DO NOT fit a new boiler to an older flue
system.
Conventional chimneys
The Contractor boilers operate at high efficiencies, with
low flue gas temperatures. All components used in the
flue system must be suitable for wet flues, and
approved for use with condensing oil boilers.
The flue should rise as vertically as possible, and
terminate at a point not subject to downdraughts and
adverse wind effects. The condensation produced in
the flue should be allowed to run back into the boiler; no
separate drain in the base of the flue is required.
Where a chimney is used, it must be lined with a
stainless steel liner suitable for use with oil-fired
condensing boilers. Before the liner is installed, the
chimney must be thoroughly cleaned of all traces of
soot and scale.
If a rigid flue is to be fitted externally, a twin-walled flue
must be used. The flue must be constructed of a
stainless steel inner skin (suitable for use with oil-fired
condensing boilers). It must also be insulated,
incorporate seals and be weather-protected.
The internal flue diameter must be 100mm (4").
Aluminium or plastic must not be used on any part of
the flue system.
The boiler will operate reliably over a wide range of
chimney draughts; as such, under normal
circumstances the flue should terminate with a standard
cowl.
Ensure that all joints on the flue system are adequately
sealed, and that no gases or condensation can escape.
Balanced flues
The Trianco balanced flue system offers greater
flexibility for siting than a conventional flue. In addition
to the siting benefit, the performance of balanced flue
boilers is virtually unaffected by high wind conditions,
as the wind pressures are applied equally to both the
air intake and flue gas discharge sections, creating the
balanced condition. Balanced flue condensing boilers
are also designed to operate at low noise levels.
Some boilers rely on case sealing; Trianco boilers do
not require case sealing as they have a sealed air duct
system that maintains the room sealed performance
even when the front casing is removed for burner
commissioning or adjustment.
The use of the balanced flue principle also enhances
the overall thermal efficiency of the boiler, as the
incoming air extracts waste heat from the flue and
returns it as pre-heated air to the burner, aiding
combustion.
Three types of balanced flue can be fitted to the boiler:
horizontal (pages 18–19), high-level horizontal
(pages 20–22), or vertical (pages 23–25). Bends can
be fitted to the vertical or high-level kits for further siting
flexibility (page 26).
During operation, a plume of condensation will
frequently discharge from the flue terminal. As such,
care should be taken when siting the flue to avoid a
nuisance to neighbouring properties. Keep the terminal
clear of infrared sensing devices, such as those used to
control security lighting or alarms. Positioning of flues
under balconies and within carports should also be
avoided.
The flue terminal should not be positioned where the
products of combustion could enter the building (see fig
14). Additional clearances may be allowed to prevent
plume nuisance (fig 15). If the terminal is less than 2
metres above ground level or any other place to which
a person has access, the terminal must be protected by
an appropriate guard. As the system operates under
positive pressure, it is essential that all flue joints are
sealed.
Trianco balanced flue kits have been designed for
exclusive use with Trianco boilers; as such,
compatibility with other manufacturers' boilers cannot
be guaranteed.
FIG. 13

Minimum clearances as measured from top of chimney
or rim of low-level discharge terminal. All distances in mm.
A
Directly below an opening (e.g. a window or air brick)
600
H
From a surface or boundary facing the terminal
600
B
Horizontally to an opening
600
J
From another terminal facing the terminal
1200
C
Below a gutter, eaves or a balcony (with protection)
75
K
Vertically from a terminal on the same wall
1500
D
Below a gutter, eaves or a balcony (without protection)
600
L
Horizontally from a terminal on the same wall
750
E
From vertical sanitary pipework
300
(600*)
M
Above the highest point of an intersection with the roof
600
F
From an internal or external corner
300
(600*)
N
From a vertical structure to one side
750
G
Above ground or balcony level
300
(600*)
O
Above a vertical structure less than 750mm to one side
600
* Scotland
P
From a ridge terminal to a vertical structure on the roof
1500
FIG. 14
Where pluming may cause a nuisance, additional clearances can be observed
(a) –Do not site within carports
(b) –Terminals under 2.1 metres from ground level should not be positioned near paths, access routes,
patios, or parking areas closer than 2.5 metres to the terminal.
(c) –Terminals should not be positioned under a roof.
(d) –Terminals should be positioned at least 1 metre from any side or top of a roof window.
(e) –Terminals should be positioned at least 1 metre from an opening or below a gutter, eaves or balcony.
(f) –Horizontal terminals should be a minimum of 2.5 metres from a facing wall, building or boundary.
FIG. 15

Horizontal balanced flue assembly
(kits 2334 & 2335)
Before starting, ensure the placement of each section
has been identified and that all 'o'-ring seals are in
position and well-lubricated.
Important: it is essential that the flue inclines slightly
up from the boiler to allow condensation to run to the
drain.
Having decided the position of the boiler, mark out
the position of the terminal and cut a circular hole
130mm diameter in the wall (see figs 17–18).
Remove the boiler top casing and the four nuts that
hold the flue socket and gasket to the top of the
heat exchanger. Remove the flue socket, but leave
the gasket in place.
Fit the sealing plate (item 4, fig 16) over the four
studs and place the terminal gasket (3) over the
sealing plate. Position the boiler.
Assemble the flue by sliding the terminal section
(2) into the elbow section (1), ensuring that all 'o'-
rings (6) are in position. Slide the completed
assembly through the wall from the inside.
Slide the flue mounting plate on the elbow section
over the four studs on the top of the heat
exchanger and secure in position using the four
nuts previously removed.
Adjust the terminal length as required, ensuring a
minimum distance of 140mm is kept from the end
of the terminal to the external face of the wall. See
figs 18–19 for allowable distances.
Connect the air hose from the burner to the socket
on the near end of the flue, using the jubilee clip
provided.
To ensure that any condensate produced in the
flue drains away correctly, incline the flue 1°
upwards from the boiler. Seal around the terminal
on the inside and outside wall with an appropriate
material.
As the flue operates under positive pressure, all
flue joints must be well-sealed. To aid assembly, it
may be necessary to apply a thin bead of silicone
grease to all flue joints that incorporate 'o'-ring
seals. All joints that do not incorporate 'o'-ring
seals should be sealed with silicone sealant.
As the boiler produces condensate during normal
running, it is important that all seals are made and the
correct gaskets used.
Where the terminal is positioned below 2 metres, or in a
place accessible to people, an approved terminal guard
will be required. A suitable stainless steel terminal
guard is available from TR Engineering (part code
223920).
FIG. 16

Model
Dim 'A'
15–20
746mm
20–26
746mm
29–36
794mm
Model
Dim 'A'
15–20
746mm
20–26
746mm
29–36
794mm
2334 –600mm Horizontal Balanced Flue Kit
2335 –1000mm Horizontal Balanced Flue Kit
FIG. 17
FIG. 18

High-level balanced flue assembly
(kit 2357 in conjunction with 2355 or 2356)
Before starting, ensure the placement of each pipe
section has been identified (fig 19), and that all 'o'-rings
are in position and are well lubricated. Any white pipe
exposed to the elements should be protected with a
suitable material. Place all weld seams to the rear.
Important: it is essential that the horizontal flue section
inclines slightly up from the boiler to allow condensation
to run back to the drain.
Before assembly, determine the length of flue required
and if necessary discard the middle section. See
adjacent for details of different available flue lengths.
Having decided the position of the boiler, mark the
position of the terminal and cut a circular hole
130mm diameter through the wall.
Remove the boiler top casing and the four nuts that
hold the flue socket and gasket to the top of the
heat exchanger. Remove the flue socket, but leave
the gasket in place.
Referring to fig 19, secure items 8,7,6 &5 in
order on to the top of the heat exchanger, using the
nuts previously removed.
Fit the lower flue section (4) to the spigot (6)—now
situated on top of the heat exchanger—and ensure
the hose connection is directed to the front.
Fit the flue mid-section (3)—and any other optional
flue lengths—to the preceding flue lengths in the
same manner, pushing firmly down until the outer
sections meet (but do not overlap). Use the
clamping strap (2) to secure the outer sections
together.
Fit the horizontal flue elbow (item 1, fig 20) to the
top of the flue mid-section. Push firmly together
until the outers meet and secure with the clamping
strap.
Slide the terminal (4) into the horizontal mid-
section (2). Adjust the horizontal length as
required, ensuring a minimum distance of 140mm
is kept from the end of the terminal to the external
face of the wall. Seal the outer horizontal sections
together with a suitable material. See figs 21–22
for allowable distances.
Slide the completed terminal assembly through the
wall from the inside and fit to the flue elbow. Push
firmly together until the outers meet and secure
with the remaining clamping strap.
Use the jubilee clip provided to secure the air hose
from the burner to the hose connection on the
lower flue section.
Remove the tabs from the cutout in the boiler top
casing and fit the casing in position around the flue.
Perform a final check of the flue. Ensure clamping
straps are located over all relevant flue joints.

To ensure that any condensate produced in the
flue drains away correctly, incline the flue 1°
upwards from the boiler. Seal any remaining gaps
in the wall around the flue with a suitable material.
Should the height of the flue (figs 21–22) not meet your
requirements, alternative heights can be achieved by
discarding and adding different lengths. The vertical
mid-section (item 3, fig 19) can be discarded to
subtract 750mm from the total height. In this case, the
horizontal elbow should instead be fitted to the lower
flue section (4) in the same manner.
Alternatively, additional sections of pipe can be
purchased to meet more specific requirements.
Additional 45° elbows can also be purchased to offset
the vertical flue run. See page 26 for details.
For outputs 15–26 kW, the total flue run—vertical and
horizontal—must not exceed 6000mm. For outputs of
29–36 kW, the total flue run must not exceed 4000mm.
Any 45° elbows contribute 500mm each to the
calculation. The 90° bend contributes 1000mm.
Where the terminal is positioned below 2 metres, or in a
place accessible to people, an approved terminal guard
will be required. A suitable stainless steel terminal
guard is available from Trianco (part code 223920).