VOKERA ProCombi 85 HE Quick guide

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Installation & Servicing Instructions
THESEINSTRUCTIONS
TO BE RETAINED
BY USER 0694

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Contents
Design principles and operating sequence Page
1.1 Principle components 4
1.2 Mode of operation (at rest) 4
1.3 Mode of operation (heating) 4
1.4 Mode of operation (DHW) 4
1.5 Safety devices 4
Technical data Page
2.1 Central heating 5
2.2 Domestic hot water 5
2.3 Gas pressure 5
2.4 Expansion vessel 5
2.5 Dimensions 5
2.6 Clearances 5
2.7 Connections 5
2.8 Electrical 5
2.9 Flue details 5
2.10 Efficiency 5
2.11 Pump duty 6
2.12 Appliance 6
General requirements (UK) Page
3.1 Related documents 7
3.2 Location of appliance 7
3.3 Gas supply 7
3.4 Flue system 7
3.5 Air supply 7
3.6 Water circulation 7
3.6.1 Pipework 8
3.6.2 Automatic by-pass 8
3.6.3 Drain cocks 8
3.6.4 Air release points 8
3.6.5 Expansion vessel 8
3.6.6 Fillingpoint 8
3.6.7 Low pressure sealed system 8
3.6.8 Frequent filling 8
3.7 Electrical supply 8
3.8 Showers 8
3.9 Mounting on a combustible surface 9
3.10 Timber framed building 9
3.11 Inhibitors 9
Installation Page
4.1 Delivery 10
4.2 Contents 10
4.3 Unpacking 10
4.4 Preparation for mounting the appliance 10
4.5 Fitting the flue 10
4.5.1 Concentric horizontal flue 10
4.5.2 Concentric vertical flue 11
4.6 Connecting the gas and water 12
4.6.1 Gas 12
4.6.2 Flow and return 12
4.6.3 Cold water inlet 12
4.6.4 Hot water outlet 12
4.6.5 Safety valve 12
4.6.6 Condense pipe 12
4.7 Electrical connections 13
4.7.1 Casing removal 13
4.7.2 Appliance terminal block 13
4.7.3 Connecting the mains (230V) input 13
Commissioning Page
5.1 Gas supply installation 14
5.2 The heating system 14
5.3 Initial filling of the system 14
5.4 Initial flushing 14
5.5 Filling the hot water system 14
5.6 Pre-operation checks 14
5.7 Initiallighting 14
5.7.1 Checking burner pressures 14
5.8 Final flushing of the heating system 14
5.8.1 Inhibitors 14
5.9 Setting the boiler operating temperature 14
5.9.1 Setting the DHW temperature 15
5.10 Setting the system design pressure 15
5.11 Regulating the hot water 15
5.11.1 Changing the flow restrictor 15
5.11.2 Regulating the central heating system 15
5.12 Final checks 15
5.13 Instructing the user 15
5.14 Technical assistance 15
Servicing instructions Page
6.1 General 16
6.2 Routine annual servicing 16
6.3 Replacement of components 16
6.4 Component removal procedure 16
6.5 Pump assembly 16
6.6 Safety valve 16
6.7 Automatic air release valve 16
6.8 Water pressure switch 17
6.9 Pressure gauge 17
6.10 Primary thermistor 17
6.11 High limit thermostat 17
6.12 PCB 17
6.13 Gas valve 17
6.14 Integral time switch 18
6.15 Electrode, burner thermostat, burner & injectors 18
6.16 Flue fan 18
6.17 Main heat exchanger 19
6.18 Air pressure switch 19
6.19 Flow restrictor 19
6.20 DHW flow switch 19
6.21 DHW heat exchanger 20
6.22 Valve actuator 20
6.23 Divertor valve cartridge 20
6.24 DHW thermistor 20
6.25 Automatic by-pass 20
6.26 DHW non-return valve 20
6.27 Expansion vessel 20
6.27.1 Expansion vessel removal (with sufficient clearance above) 20
6.27.2 Expansionvesselremoval (withinsufficientclearanceabove) 21
6.28.1 Latent heat collector 21
6.28.2 Dismantling the latent heat collector 21
6.29 Condense trap removal 21
Checks, adjustments and fault finding page
7.1 Checking appliance operation 22
7.2 Appliance mode of operation 22
7.2.1 Selector switch in the OFF position 22
7.2.2 Selector switch in the hot water only position 22
7.2.3 Selector switch in the heating & hot water position 22
7.2.4 Appliance functions 22
7.2.5 DHW mode 22
7.2.6 Heating mode 23
7.3 Checking & adjusting burner pressure 24
7.3.1 Setting the maximum burner pressure 24
7.3.2 Setting the minimum burner pressure 24
7.3.3 Setting the minimum CH output 24
7.4 Combustion analysis test 24
7.5 Checking the expansion vessel 25
7.6 External faults 25
7.6.1 Installation faults 25
7.7 Electrical checks 25
7.7.1 Earth continuity test 25
7.7.2 Short circuit check 25
7.7.3 Polarity check 25
7.7.4 Reversed polarity or supply fault 26
7.7.5 Resistance to earth check 26
7.8 Fault finding 26
7.8.1 Replacing the main PCB 26
7.9 Fault codes 26
7.10 Fault finding 27-32
Wiring diagrams Page
8.1 External wiring 33
8.2 Typical control applications 33
8.3 Room thermostat 33
8.4 Other controls 33
Functional diagram 34
L.P.G. instructions Page
10.1 Related documents 35
10.2 Technical data 35
10.3 Converting the appliance gas supply 35
10.4 Gas supply 35
10.5 Gas supply installation 35
10.6 Checking & adjusting burner pressure 35
10.6.1 Setting the maximum burner pressure 35
10.6.2 Setting the minimum burner pressure 35

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INTRODUCTION
Fig.1GeneralLayout
1 Dischargevalve
2 Gas valve
3 Modulatorcoil
4 Pressureswitch
5 Condensetrap
6 Ignitiontransformer
7 Expansion vessel
8 Electrode
9 Mainburner
10 Mainheatexchanger
11 Latentheatcollector
12 Flue gas analysis test point
13 Flueoutlet
14 Air intake
15 Differentialpressureswitch
16 Siliconepressuretube(-)
17 Siliconepressuretube(+)
18 Fanassembly
19 CHNTCsensor
20 High limit thermostat
21 Combustionchamber
22 Condensatepressureswitch
23 Auto air vent (AAV)
24 Pump
25 DHWflow switch
26 DHWsensor
27 Domestichotwaterheatexchanger
28 Divertervalve motor
29 Pressuregauge
30 DHWposition
31 Mode selector switch
32 Faultindicatorled
33 CHposition
34 Timeclock
The PROCombiHE range ofappliancesis comprised of
2modelsofhigh-efficiency combination boiler with inputs
to heating & DHW of 25, 29 kW respectively.Each appli-
ance - by design - incorporates electronic ignition, circu-
lating pump, expansion vessel, safety valve, pressure
gaugeand automatic by-pass.
The PRO Combi HE range is produced as room sealed,
category II2H3P appliances, suitable for internal wall
mountingapplications only. Theyare provided with a fan
poweredflueoutletwithanannularcoaxialcombustionair
intake that can be rotated - horizontally - through 360
degreesforvarioushorizontalorverticalapplications. The
PROCombiHErangeisapprovedforusewithC12&C32
type flue applications.
These appliances are designed for use with a sealed
system only; consequently they are not intended for use
on open vented systems
Fig. 1 29 30 31 33 34
32

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SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE
Fig. 2
1.1 PRINCIPLE COMPONENTS
●A fully integrated electronic control board fea-
turing electronic temperature control, anti-cy-
clecontrol,pumpover-run, LED fault indicator,
full gas modulation.
●Low-water-content, copper heat exchanger.
●Electronic ignition with flame supervision.
●Integral high-head pump.
●Fan.
●Air pressure switch.
●Expansion vessel.
●Water pressure switch.
●Two-stage gas valve.
●Pressure gauge.
●Safety valve.
●Condense switch.
1.2 MODE OF OPERATION (at rest)
When the appliance is at rest and there are no
requests for heating or DHW, the following func-
tions are active:
●Frost-protection system: the frost-protection
system protects the appliance against the risk
offrostdamage.Shouldthetemperatureofthe
appliance fall to 5 °C, the boiler will function in
the heating mode at minimum power until it
reaches 35°C.
●Anti-blockfunction:theanti-blockfunctionena-
blesthepumpanddivertorvalveactuator,tobe
energised for short periods, when the appli-
ancehasbeeninactiveformorethan19-hours.
1.3 MODE OF OPERATION (Heating)
Whenthereisarequestforheatviathetimeclock
and/oranyexternalcontrol,thepumpandfanare
started, the fan will then prove the air pressure
switch. At this point an ignition sequence is
enabled.
Ignition is sensed by the electronic circuitry to
ensure flame stability at the burner. Once suc-
cessfulignitionhasbeenachieved,theelectronic
circuitry increases the gas rate to 75% for a
period of 15 minutes. Thereafter, the boiler’s
output will either be increase to maximum or
modulate to suit the set requirement.
When the appliance reaches the desired tem-
perature the burner will shut down and the boiler
will perform a three-minute anti-cycle (timer de-
lay).
Whentherequest for heat hasbeen satisfied the
appliancepumpandfanmaycontinuetooperate
to dissipate any residual heat within the appli-
ance.
1.4 MODE OF OPERATION (DHW)
When there is a request for DHW via a hot water
outletortap,thepumpandfanarestarted,thefan
will then prove the air pressure switch. At this
point an ignition sequence is enabled.
Ignition is sensed by the electronic circuitry to
ensure flame stability at the burner. Once suc-
cessfulignitionhasbeenachieved,theelectronic
circuitry increases the gas rate to maximum or
willmodulateoutputtostabilisethetemperature.
In the event of the appliance exceeding the
desired temperature the burner will shut down
until the temperature drops.
WhentherequestforDHWhasbeensatisfiedthe
appliancepumpandfanmaycontinuetooperate
to dissipate any residual heat within the appli-
ance.
1.5 SAFETY DEVICES
When the appliance is in use, safe operation is
ensured by:
●A water pressure switch that monitors system
water pressure and will deactivate the pump,
fan and burner should the system water pres-
sure drop below the rated tolerance.
●A high limit thermostat that over-rides the tem-
perature control circuit to prevent or interrupt
the operation of the burner.
●An air pressure switch that requires the fan to
prove operation before the gas valve is ener-
gised.
●A pressure switch that interrupts the operation
ofthe appliance if the condensepipe becomes
blocked.
●Asafetyvalvewhichreleasesexcesspressure
from the primary circuit.
Automatic
by-pass
DHWnon
returnvalve
Safetyvalve
DHW
temperature
sensor
Diverter
valvemotor
Water
pressure
switch
AAV
latent heat
collector
Flue
outlet Air intake
Pressure
switch
Mainheat
exchanger
Gasvalve
Main
burner
CH NTC
sensor
Expansion
vessel
Pump
DHWheat
exchanger
DHW
flowswitch
CH
return
CH
flow DHW
outlet Domesticcold
water inlet

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SECTION 2 TECHNICAL DATA
Ref. Condition 15 °C , 1013,25 mbar, dry gas
NOTE: L.P.G. data refer to section 10
85 HE 100HE
2.1Centralheating
Heatinput(kW) 25.00 29.00
Maximumheatoutput@80/60°C(kW) 24.35 28.30
Minimumheatoutput@80/60°C(kW) 14.25 14.28
Maximumheatoutput@50/30°C(kW) 25.90 29.93
Minimumheatoutput@50/30°C(kW) 14.85 14.75
Minimumworkingpressure 0.5bar 0.5bar
Maximumworkingpressure 2.7bar 2.7bar
Minimumflowrate 350l/h 350l/h
2.2 Domestic hot water
Minimumoutput(kW) 9.50 9.90
Flowrate(35 °C rise) 10.2l/min 11.9l/min
Maximuminletpressure 6.0bar 6.0bar
Minimuminletworkingpressure 0.15bar 0.15bar
Minimumflowrate 2l/min. 2l/min.
2.3Gaspressures
Inlet pressureG20 20.0mbar 20.0mbar
Maximumburnerpressure 9.40mbar 9.20mbar
Minimumburnerpressure(centralheating) 3.50mbar 2.70mbar
Minimumburnerpressure(domestichotwater) 1.50mbar 1.20mbar
Grossrate(centralheating,max-min) 2.64-1.59 m3/h 3.07-1.59m3/h
Injectorssize 12x1.35mm 14x1.35mm
2.4Expansionvessel
Capacity 8litres 10litres
Maximumsystemvolume 76litres 91litres
Pre-chargepressure 1.0bar 1.0bar
2.5Dimensions
Height 780mm 780mm
Width 400mm 450mm
Depth 332mm 332mm
Dryweight 40kg 44 kg
2.6Clearances
Sides 12mm 12mm
Top 150mmfromcasingor25mmaboveflueelbow,whicheverisapplicable
Bottom 150mm 150mm
Front 600mm 600mm
2.7Connections
Flow&return 22mm 22mm
Hot&coldwaterconnections 15mm 15mm
Gas 15mm 15mm
Safetyvalve 15mm 15mm
Condense 21mm 21mm
2.8Electrical
Voltage 230V/~50hz 230V/~50hz
Powerconsumption 153W 153W
Internalfuse 2A 2A
Externalfuse 3A 3A
2.9Fluedetails(concentric)
Maximumhorizontalfluelength(60/100mm) 4.5m 4.0m
Maximumverticalfluelength(60/100mm) 5.5m 5.0m
2.10Efficiency
SEDBUK 86.9Band“B” 86.7Band“B”

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2.11 PUMPDUTY
Fig. 3 shows the flow rate available - after allowing for pressure loss through the appliance - for system
requirements. When using this graph, apply only the pressure loss of the system. The graph is based on a
20 ºC temperature differential.
Fig. 4
SECTION 3 GENERAL REQUIREMENTS
Key Location Minimum distance
A Below an opening (window, air-brick, etc.) 300 mm
B Above an opening (window, air-brick, etc.) 300 mm
C To the side of an opening (window, air-brick, etc.) 300 mm
D Below gutter, drain-pipe, etc. 25 mm
E Below eaves 25mm
F Below balcony, car-port roof, etc. 25 mm
G To the side of a soil/drain-pipe, etc. 25 mm
H From internal/external corner or boundary 300 mm
I Above ground, roof, or balcony level 300 mm
J From a surface or boundary facing the terminal 1200 mm
K From a terminal facing a terminal 1200 mm
L From an opening in the car-port into the building 1200 mm
M Vertically from a terminal on the same wall 1500 mm
N Horizontally from a terminal on the same wall 300 mm
P From a structure to the side of the vertical terminal 500 mm
Q From the top of the vertical terminal to the roof flashing As determined by the fixed collar
of the vertical terminal
2.12Appliance
NOx 94ppm-166mg/kWh 92 ppm-162mg/kWh
CO(max-min) 80ppm-80 ppm 100ppm-60 ppm
CO2(max-min) 6.75 - 3.90% 7.05- 3.50 %
CO/CO2ratio (max) 0.001to1 0.001to1
CO/CO2ratio(min) 0.002to1 0.002to1
85 HE 100HE
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
4,5
5,0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300
first speed
second speed
third speed
85 HE - 100 HE

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This appliance must be installed by a competent
personinaccordancewiththeGasSafety(Instal-
lation & Use) Regulations.
3.1 RELATED DOCUMENTS
The installation of this boiler must be in accord-
ance with the relevant requirements of the Gas
Safety(Installation & Use) Regulations, the local
building regulations, the current I.E.E. wiring
regulations, the bylaws of the local water under-
taking, the Building Standards (Scotland) Regu-
lation and Building Standards (Northern Ireland)
Regulations.
Itshould be in accordancealso with anyrelevant
requirements of the local authority and the rel-
evant recommendations of the following British
Standard Codes of Practice.
3.2 LOCATION OF APPLIANCE
The appliance may be installed in any room or
internal space, although particular attention is
drawn to the requirements of the current I.E.E.
wiring regulations and in Scotland, the electrical
provisions of the Building Regulations, with re-
specttotheinstallationoftheapplianceinaroom
or internal space containing a bath or shower.
Whenanapplianceisinstalledinaroomorinternal
spacecontainingabathorshower,theappliance
or any control pertaining to it must not be within
reach of a person using the bath or shower.
Thelocationchosenfortheappliancemustpermit
the provision of a safe and satisfactory flue and
termination. The location must also permit an
adequate air supply for combustion purposes
and an adequate space for servicing and air
circulation around the appliance. Where the in-
stallation of the appliance will be in an unusual
location special procedures may be necessary,
BS 6798 gives detailed guidance on this aspect.
A compartment used to enclose the appliance
must be designed and constructed specifically
for this purpose. An existing compartment/cup-
board may be utilised provided that it is modified
to suit.
Details of essential features of compartment/
cupboarddesignincludingairingcupboardinstal-
lationsaregiveninBS6798.Thisapplianceisnot
suitable for external installation.
3.3 GAS SUPPLY
The gas meter - as supplied by the gas supplier
-mustbecheckedtoensurethatitisofadequate
size to deal with the maximum rated input of all
the appliances that it serves. Installation pipes
must be fitted in accordance with BS 6891.
Pipe work from the meter to the appliance must
be of adequate size. Pipes of a smaller size than
the appliance gas inlet connection must not be
used. The installation must be tested for sound-
ness in accordance with BS6891.
Ifthegassupplyservesmorethanoneappliance,
it must be ensured that an adequate supply is
maintained to each appliance when they are in
use at the same time.
3.4 FLUE SYSTEM
Theterminalshouldbelocatedwherethedisper-
sal of combustion products is not impeded and
withdueregardforthedamageanddiscoloration
thatmayoccurtobuildingproductslocatednearby.
Theterminalmustnotbelocatedinaplacewhere
it is likely to cause a nuisance (see fig. 4).
Watervapourwillcondenseonleavingthetermi-
nal and the effect of such pluming must be
considered.
BS5440 PART 1 FLUES
BS 5440 PART 2 FLUES & VENTILATION
BS5449 PART 1 FORCEDCIRCULATIONHOTWATERSYSTEMS
BS5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES
(2ND FAMILY GASES)
BS 6798 INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60kW
BS 6891 LOW PRESSURE INSTALLATION PIPES
BS 7074 PART 1 APPLICATION, SELECTION AND INSTALLATION OF EXPANSION VESSELS AND
ANCILLARY EQUIPMENT FOR SEALED WATER SYSTEMS
If installed less than 2m above a pavement or
platform to which people have access (including
balconies or flat roofs) the terminal must be
protected by a guard of durable material. The
guard must be fitted centrally over the terminal.
Refer to BS 5440 Part 1, when a terminal is sited
less than 1m below a plastic gutter, or less than
500mm below a painted surface, a suitable one
metre long heat shield should be fitted.
3.5 AIR SUPPLY
The following notes are intended for general
guidance only.
Thisapplianceisaroom-sealed,fan-fluedboiler,
consequentlyit doesnot require a permanent air
vent for combustion air supply.
When installed in a cupboard or compartment,
ventilation for cooling purposes is also not re-
quired.
3.6 WATER CIRCULATION
Detailedrecommendationsaregivenin BS 5449
Part 1 and BS 6798. The following notes are for
general guidance only.

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Fig. 5a
3.6.7 LOW PRESSURE SEALED SYSTEM
An alternative method of filling the system would
be from an independent make-up vessel or tank
mounted in a position at least 1 metre above the
highest point in the system and at least 5 metres
above the boiler (see fig. 5a).
The cold feed from the make-up vessel or tank
must be fitted with an approved non-return valve
and stopcock for isolation purposes. The feed
pipe should be connected to the return pipe as
close to the boiler as possible.
3.6.8 FREQUENT FILLING
Frequent filling or venting of the system may be
indicative of a leak. Care should be taken during
the installation of the appliance to ensure all
aspects of the system are capable of withstand-
ing pressures up to at least 3 bar.
3.7 ELECTRICAL SUPPLY
The appliance is supplied for operation on 230V
@ 50Hz electrical supply; it must be protected
with a 3-amp fuse. The method of connection to
the mains electricity supply must allow for com-
plete isolation from the supply. The preferred
method is by using a double-pole switch with a
contact separation of at least 3mm. The switch
must only supply the appliance and its corre-
sponding controls, i.e. time clock, room thermo-
stat, etc. Alternatively an un-switched shuttered
socket with a fused 3-pin plug both complying
with BS 1363 is acceptable.
3.8 SHOWERS
Iftheapplianceisintendedforusewithashower,
the shower must be thermostatically controlled
andbe suitableforusewitha combinationboiler.
3.6.1 PIPEWORK
ItisrecommendedthatcoppertubingtoBS2871
Part 1 is used in conjunction with soldered capil-
lary joints.
Where possible pipes should have a gradient to
ensureairiscarriednaturallytoairreleasepoints
and that water flows naturally to drain cocks.
Exceptwhereprovidingusefulheat,pipesshould
beinsulatedtoavoidheatlossandinparticularto
avoid the possibility of freezing. Particular atten-
tion should be paid to pipes passing through
ventilated areas such as under floors, loft space
and void areas.
3.6.2 AUTOMATIC BY-PASS
The appliance has a built-in automatic by-pass.
However it may be necessary to fit an external
bypass should the design of the heating system
require such. In any case, the design of the
system should be such that it prevents boiler
‘cycling’.
3.6.3 DRAIN COCKS
Thesemust be located in accessible positions to
facilitate draining of the appliance and all water
pipes connected to the appliance. The drain
cocks must be manufactured in accordance with
BS 2879.
3.6.4 AIR RELEASE POINTS
Thesemustbepositionedatthehighestpointsin
thesystemwhereairislikely to be trapped. They
should be used to expel trapped air and allow
complete filling of the system.
3.6.5 EXPANSION VESSEL
The appliance has an integral expansion vessel
to accommodate the increased volume of water
when the system is heated. It can accept up to 8
litres(25kW)or10litres(29kW)ofexpansionfrom
within the system, generally this is sufficient,
howeverifthesystemhasanunusuallyhighwater
content,itmaybenecessarytoprovideadditional
expansioncapacity (see 6.19).
3.6.6 FILLINGPOINT
Anapprovedmethodforinitialfillingofthesystem
and replacing water lost during servicing etc. is
required (see fig. 5). This method of filling must
comply with the current Water Supply (Water
Fittings) Regulations 1999 and Water Bylaws
2000 (Scotland).
Fig. 5
control valve
temporary
connection control valve
supply pipe
double check
valve
flow/return
pipe
Make-up vessel
or tank
Automatic
air-vent
Non-return
valve Stopcock
5.0 metres minimum
Heating
return

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3.9 MOUNTINGONACOMBUSTIBLESURFACE
If the appliance is to be fitted on a wall of
combustible material, a sheet of fireproof mate-
rial must protect the wall.
3.10 TIMBER FRAMED BUILDING
If the appliance is to be fitted in a timber framed
building,itshouldbefittedinaccordancewiththe
Institute of Gas Engineers publication (IGE/UP/
7) ‘Guide for Gas Installations in Timber Frame
Buildings’.
3.11 INHIBITORS
Itisrecommendthataninhibitor-suitableforuse
with copper and aluminium heat exchangers - is
used to protect the boiler and system from the
effects of corrosion and/or electrolytic action.
The inhibitor must be administered in strict ac-
cordance with the manufacturers instructions*.
*Watertreatmentofthecompleteheatingsystem
- including the boiler - should be carried out in
accordance with BS 7593 and the Domestic
Water Treatment Association’s (DWTA) code of
practice. Fig. 6a
Fig. 6

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Using the template provided, mark and drill a
115mm hole for the passage of the flue pipe. The
hole should be drilled level to ensure any con-
densefluidthatformswilldrainbacktotheboiler.
The fixing holes for the wall-mounting bracket
should now be drilled and plugged, an appropri-
ate type and quantity of fixing should be used to
ensure that the bracket is mounted securely.
Once the bracket has been secured to the wall,
mount the appliance onto the bracket.
FITTING THE HORIZONTAL FLUE KIT
Carefullymeasurethedistancefromthecentreof
the appliance flue outlet to the edge of the fin-
ished outside wall (dimension X). Add 65mm to
dimensionXtogiveyoudimensionY(seefig7A).
Measure dimension Y from the terminal end of
the concentric flue pipe and cut off the excess
from the 100mm pipe ensuring any burrs are
removed. Using the cut-off piece of 100mm pipe
as a guide, mark and cut the same length of pipe
from the inner 60mm pipe (the 60mm should
always project past the 100mm pipe by 30mm).
Pass the concentric flue pipe through the previ-
ously drilled hole. Fit the flue bend to the boiler
flue outlet and insert the concentric flue pipe into
the flue bend ensuring the correct seal is made.
Usingtheclamps,gaskets,andscrewssupplied,
secure the flue bend to the appliance flue spigot
and the flue terminal.
NOTE
Fit the internal (White) trim to the flue assembly
prior to connecting the flue pipe to the bend.
Fig. 7
Boiler
outer
clamp
Terminalor
extension
SECTION 4 INSTALLATION
4.1 DELIVERY
Duetotheweightoftheapplianceitmaybenecessary
for two people to lift and attach the appliance to its
mounting.Theapplianceiscontainedwithinaheavy-
dutycardboardcarton.Laythecartononthefloorwith
the writing the correct way up.
4.2 CONTENTS
Contained within the carton is:
●the boiler
●the wall bracket
●appliance template
●anaccessoriespackcontainingapplianceserv-
ice connections and washers
●the instruction pack containing the installation
& servicing instructions, user instructions,
Benchmarklogbook,guaranteeregistrationcard
and a 3-amp fuse.
4.3 UNPACKING
At the top of the carton pull both sides open - do
notuseaknife-unfoldtherestofthecartonfrom
around the appliance, carefully remove all pro-
tective packaging from the appliance and lay the
accessories etc. to one side. Protective gloves
shouldbeusedtolifttheappliance,theappliance
back-frame should be used for lifting points.
4.4 PREPARATION FOR MOUNTING THE APPLI-
ANCE
The appliance should be mounted on a smooth,
vertical,non-combustiblesurface,whichmustbe
capable of supporting the full weight of the appli-
ance. Care should be exercised when determin-
ing the position of the appliance with respect to
hidden obstructions such as pipes, cables, etc.
When the position of the appliance has been
decided - using the template supplied - carefully
mark the position of the wall- mounting bracket
(see fig. 6) and flue-hole (if applicable).
4.5 FITTING THE FLUE
The top flue outlet permits both horizontal and
vertical flue applications to be considered.
4.5.1 CONCENTRIC HORIZONTAL FLUE
(For concentric vertical flue, see section 4.5.2).
The appliance flue outlet elbow can be rotated
through 360º on its vertical axis. In addition the
fluemaybeextendedfromtheoutletelbowinthe
horizontalplane (see2.9). A reduction must also
be made to the maximum length (see table
below) when additional bends are used.
Bend Reduction in maximum flue length for each bend
45º bend 0.5 metre
90º bend 1.0 metre
Reduction for additional bends
Part No. Description Min-Max Length
489 Telescopic flue terminal kit 350/500mm
491 Horizontal flue kit for use with 1000 mm
add. bends & extensions
492 0.5m extension 500 mm
493 1.0m extension 1000 mm
494 2.0m extension 2000 mm
495 45º bend (pair) N/A
496 90º bend N/A
499 Wall bracket N/A
Horizontal flue terminals and accessories