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Installation and servicing manual

1. L 1 39 5 m terminal 5 15 system with concentric pipes for flat or sloping roofs Extensions with two separate pipes fig 24 Maximum distance T L 21 21 42 metre Terminal Minimum distance L 0 5 0 5 1metre Terminal Exhaust terminal must not be cut NOTE L L1 37m If bends are used in the exhaust flue then horizontal Sections must be avoided and there must be a 1 5 slope Towards the boiler 25 mm fall per metre Maximum distance D L L1 39 5 metre Terminal Minimum total length 2 metre NOTE Exhaust flue must slope 1 5 down towards the IMPORTANT Please lubricate the boiler 25 mm fall per metre internal part of the seals before fitting Exhaust suction system with two separate pipes through a single vertical wall fig 26 Available on request from THE WHITE BOILER COMPANY Mann Chartists way Morley Leeds West Yorkshire Min distance between pipe 50 mm ENGLAND LS27 9ET U K Tel 0113 252 7007 Maximum distance D 2 L L1 2 37 metre Minimum distance D L L1 1 metre
2. TO CLEAN AND REMOVE REPLACE CONDENSING TRAP Fig 50 Remove front panel fig 39 bottom and left side panels fig 40 Remove the securing clip and pull out the plastic pipe that connects the condensing trap at the heat exchanger Unscrew the nut that fastens the condensing trap to the depression chamber and remove it If the side panel can not be removed then remove the gas valve see sec 8 10 and continue with the above instructions Replace in reverse order Head cap Siphon adapter Seal Condensing trap unit Float Float bracket Seal Cap TO REMOVE PANEL CONTROL BOX Fig 51 52 53 Remove front panel fig 39 Pull forward the control panel box with both hands until it is slightly out of the boiler As doing so move the box over to the left while still pulling it forward until the control box becomes free Lift and fix the box on the depression chamber with the service retaining clips NES With both hands move the con
3. REMOVE REPLACE PUMP Fig 48 Remove front and bottom panels fig 39 40 Close the on off valves for the heating circuit and drain the water at drain point fig 36 Detach the supply wire connector from the pump Unscrew the nut that fastens the pump to the CH pipe and remove the pump and remove the securing clip at the pump manifold Replace in reverse order NOTE Always use new O ring Automatic air vent Pump wire connector Pump TO REMOVE REPLACE D H W DIVERTER VALVE MECHANISM Fig 47 Remove front and bottom panels fig 39 40 Remove the panel control box sect 8 23 Close the on off valves for the heating circuit and drain the water at drain point fig 36 Remove flow detector and unscrew DHW diverter valve Replace in reverse order NOTE Always use new O ring Flow detector switch DHW diverter mechanism Safety relief valve DHW sensor TO REMOVE REPLACE AUTOMATIC AIR VENT Fig 48 Remove front and bottom panels fig 39 40 Remove the panel control box sect 8 23 Close the on off valves for C H circuit and drain the water from at drain point Fig 36 Remove the clip and pull the automatic a
4. THE WHITE BOILER COMPANY WH 100 130 HIGH EFFICIENCY CONDENSING COMBINATION BOILER SHORT LIST OF SPARE PARTS AND FLUE ACCESSORIES G C Description Part No FUS010150 ______ Potentiometer assembly Water pressure gauge O Digital display 7 msrmmentpanelabe memalfuse315A O CRi0250 _____ Comolbad O _______ O _____ Pump Manfod OTng o _____ Pump Prsswegau VAS130050 Expansionvassel S SCA130150 Heat exchanger WH 130 Sane oo ERE WIE TRA130050 Sparkigniter ______________ igniter e caisso ______ _ _____ Temperature fue sensor _____ _______ OO O _____ _______ thermostat _____ BumerWH180 O O BRUIZ0100 BumrWHio 22 corso 5 Semigeecrode F 24 0060 JCH sensor 25 VENI3080 251 VEN130100 Fan mixer WH 100 assembly 252 VEN130150 Fan mxerWH 130 assembly 26 GUAMOOD0 27 RACIO0500 j Condensimgtap 28 VALISO0 Gasva
5. TO REMOVE REPLACE EXPANSION VESSEL Fig 47 Remove front casing sect 8 1 4 and the bottom panel Remove the bottom panel and the right side panel Drain the CH circuit Unscrew the fixing bracket Unscrew the nut connecting the expansion vessel and lift up the vessel and remove Replace in reverse order NOTE Always use new gasket nscrew Gasket 1 gt Unscrew remove the bracket Unscrew and Lift up expansion vessel TO REMOVE REPLACE PLATE HEAT EXCHANGER Fig 48 49 Remove front casing sect 8 1 4 Remove the bottom panel Plate heat exchanger O ring Follow instruction to drop down control box sect 8 20 Close off on off valves for CH circuit and DHW circuit and drain the boiler and drain hot water from the lowest hot water tap Unscrews the two allen screws that connect the DHW heat exchanger and pull it out from the boiler Fig 48 If necessary the pipes from the flow manifold may have to be remove for easier access Lift up the plate heat exchanger Replace in reverse order NOTE Always use new O rings TO REMOVE REPLACE DIVERTER VALVE MOTOR Fig 50 Remove front casing sect 8 1 4 Detach the electrical plug and remove the re
6. Flashing Flashing Flashing Flashing plate N plate plate plate I 600 mm Flat roof Straight Flue Straight Flue 90 Offset Flue 135 Offset Flue 25 Max 25 20 22 5 plus Terminal plus Terminal plus Terminal plus Terminal NOTE If using Flue arrangement in fig 27 then the 125x100 Flue reducer TABLE 9 must be purchased separately Description IMPORTANT Please lubricate the PR5094110A Straight flue header sample point internal part of the seals before 60 100 fitting PRO110300 Flue Extension 80 125 L1000 RID110050 125 80 to 100 60 Flue reducer CUR110250 45 flue bend 80 125 TE WATE BOILER COMPANY CUR110300 90 elbow flue bend 80 125 Chartists way Morley Leeds West Yorkshire TERO010050 Horizontal Flue Terminal 80 125 ENGLAND 1527 U K TER110200 Vertical Flue Terminal 80 125 Tel 0113 252 7007 TEGO60050 Flashing sleeve slate ASSEMBLE BOILER Fitting valve pack Remove plastic caps from boiler connection and fit valves as per fig 29 using washers provided
7. 6 15 HANDING OVER TO THE USER i 6 15 1 After completion of installation commissioning of the system the installer should hand over to the Householder by taking the following actions Hand the User s Instructions to the Householder and explain His Her responsibilities under the Gas Safety Regulations 2000 Explain and demonstrate the lighting and shutting down procedures SECTION 7 SERVICING INSTRUCTIONS The White Boiler Company is a member of the Benchmark initiative and fully supports the aims ofthe programme Benchmark was instructed to improve the standards of installation and commissioning of central heating systems in the UK and to encourage in the regular servicing of all central heating systems to ensure safety and efficiency COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Combustion testing must be carried out by competent person using a combustion analyser conforming to BS7927 During routine servicing and after any maintenance or change of part of the combustion circuit the following must be checked The integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals The operational dynamic working gas inlet pressure at maximum rate The
8. 4 Gas inlet Heating system gt Heating system non return Safety relief L Cold water system Y o feed Domestic hot water outlet KEY 1 Condensate drain 10 Fan 19 Low water pressure 2 Burner 11 Heat exchanger switch 3 Flue gas exhaust manifold 12 CH return 20 Diverter valve motor 4 Flue temperature sensor 13 Gas valve 21 DHW sensor 5 Commisioning manual air vent 14 Diferential water pressure switch 22 Plate heat exchanger 6 CH flow 15 Water pressure gauge 23 Safety pressure relief valve 7 Overheat thermostat 16 Expansion vessel 24 Gas service cock 8 Spark electrode 17 Auto air vent 25 Compression ball valves 9 Sensing electrode 18 Circulation pump SECTION 1 INTRODUCTION 11 SECTION 2 2 1 2 2 The boiler is designed for the production of central heating and domestic hot water combined in one unit It is fitted with an automatic domestic hot water priority valve A summer winter switch is fitted on the control panel With the Summer only switch position being for domestic hot water The summer winter position being for central heating with domestic hot water priority The boiler is equipped with a front cover which can be removed for servicing The data badge with technical data is placed on the lower part of the left hand side panel Fig 1 Illustrates the general layout of components
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10. eu eu si ji NOILISOd 1VNIIH3L 31173 any EIA 0 346 1 009 sujejp pue sedid JR 67 pue 002 Je ioq smol Je ioq eui 10 Gz 1528 10 seeJDep G aq suonoes ejuozuou iv edid y jesodsip ayes 10 SMO ejesuepuoo y JEU einsue seeJfep q Jo ur inq seu eu L SS N seuepunoq uoneleJ ui sjeuiuJe Bus ueye si yeu OPS SA eouesinu e esneo ssejun 0 009 IMPORTANT NOTICE If the flue terminates below a balcony above the ground above a flat roof to which people have access then a suitable terminal guard must be fitted PRO110100 Fit only recommended FLUE TERMINAL GUARD by securing concentrically around terminal with screws Available on request from The White Boiler Company Morley Leeds West Yorkshire ENGLAND LS27 9ET UK Tel 0044 0 113 252 7007 IMPORTANT The following notes are intended for general guidance The boiler MUST be installed so that the terminal is
11. Check operating system FLUE TEMPERATURE SEQUENCE CODE Is 31 displayed Check Replace flue sensor RESET THE BOILER Push the Reset button on Digital Display and check LCD if illuminate Does the DHW temperature Check Replace DHW potentiometer Check Replace DHW sensor stabilise at set point Yes END OF DOMESTIC HOT WATER TEST NOTE See Section 10 page 51 for LED DISPLAY CODE ZH GG 069 peeds ue uiui ZHSS 069 peeds ue ZH OLZ udi 0029 peeds xeW MHA ZHOLZ udi 0029 peeds MHA uonoeuuoo peeds ue uonisod ZHO8 oops peeds 2 08 OOS peeds peeds go 9520 90720 06 ZOO _40 ose 6 0720 06 ZOO joy deex uM 09 eu61p OEL HM bul 00L HM 338 jou JO UBYOJG eqoJd DIN 10 9 1 1 y N 4 0 peyoojq 40 eunsseJd 82 Bum pue 1 pejoeuuoo jou JO uexoJq JOSUBS H2 2 JOU JO uexoJq JOSUaS MHA 90 Josues 94njeJeduiJej 70 jou JO U9X0JQ SI BU
12. TWIN FLUE INSTRUCTIONS This part of the installation manual covers the installation and fixing instructions of the twin flue eccentric flue duct systems only When ordering twin flue it must be stated for WH 80 90 T range Typical installation procedures are illustrated by drawings Remove the front panel of the case sect 8 1 Unscrew the screw item 66 fig 17 on the flue adapter Make sure that the flue manifold rubber seal is located into the flue manifold and lubricate the internal part of the seal before assembly Locate the header gasket on the twin flue header and push into the flue adaptor making Straight flue sure that the inner plastic exhaust locates firmly in the outlet spigot of the flue manifold and screw the securing screw that secure the twin flue header on the boiler Locate the 2 x 80 mm O rings in the twin flue header and lubricate the internal part of the seal before assembly to ensure easy snug fit Figures show the versatility of this flueing system Measurements and bends must be calculated correctly so as not to oversize maximum flue lengths All located O rings must be lubricated with IMPORTANT Silicone grease to ensure a snug fit These instructions must be read in conjunction with the main installation and NOTE Exhaust flue must slope 1 5 down servicing instructions towards the boiler 25
13. NO 5 SEDBUK IP XA D GENERAL REQUIREMENTS SAFETY Gas Safety Installation and Use Regulations It is law that all gas appliances are installed and serviced by a Gas Safe registered installer in accordance with the above regulations and these installation instructions All registered installers carry a Gas Safe 1 0 card and registration number Both should be recorded in your Benchmark commissioning checklist You can check your installer on the Gas Safe register www gassaferegister co uk Failure to install appliances correctly could lead to prosecution It is in your own interest and that of your safety to ensure the law is complied with Check the boiler and flue is the correct type for installation undertaken The installation of the boiler MUST be in accordance with the latest 1 BS 7671 Wiring Regulations local building regulations bye laws of the local water authority the building regulations and the Building Standards Scotland and any relevant requirements of the local authority GENERAL INFORMATION Both the user and the manufacturer rely heavily on the installer whose job it is to install the combination boiler and connect it to a correctly designed heating system Acquaint yourself with the relevant British Standards concerning installation requirements If you need further advice on any points contact the Technical Services Office on 0113 2527007 who would be pleased to he
14. plus 2 bend 45 and Combi ridge 64 Flue exhaust duct extension 65 Flue manifold rubber seal 66 Securing screw 68 Flue starter 69 Air sample point IMPORTANT Please lubricate the internal part of the seals before being fitted IMPORTANT Please lubricate the internal part of the seals before being fitted IMPORTANT These instructions must be read conjunction with the main installation and servicing instructions As with all flues the kits must be installed taking due account of the current issue of BS 5440 parts 1 amp 2 and timber frame housing 2 is referenced to the Institute of Gas Engineers Document IGE UP 7 Also note that the requirements will vary depending upon the kit being installed Guidance is provided but unless otherwise stated always comply with the recommendations of the relevant codes of practice Part No SDO110050 PRO110200 CUR110150 CUR110200 GRI110050 GRI110100 TERO060110 5 8 INSTALLATION INSTRUCTIONS FOR TWIN FLUE PIPE ECCENTRIC FLUE DUCT SYSTEM Description Twin flue header F80 F80 Straight pipe L 1000 80 90 elbow bend 80 45 bend 80 Air inlet terminal 80 Exhaust terminal 80 Vertical eccentric flue Terminal TWIN FLUE INSTRUCTIONS This part of the installation manual covers the installation and fixing instructions of the twin flue eccentric flue duct systems only When ordering tw
15. Boiler TERMINATION SOAK AWAY External wall re ry Termination to soack away CONVERTING THE APPLIANCE TO DIFFERENT GAS TYPES Boilers are factory set to work for use with Natural gas or LPG gas This is clearly marked on the packing and boiler data badge To convert a boiler from one gas to another this operation must be carried out by a qualified competent person with all necessary equipment autorised by the manufacturer It will also be necessary to obtain a data badge conversion kit directly from The White Boiler Company 5 17 5 17 1 1 Remove the case 2 Check gas mains pressure at the gas valve test nipple upstream Fig 34 with boiler operating Sect 6 8 3 Adjust Fan Speed as Sect 3 technical data 4 Measure the level of CO2 as sect 6 9 and adjust to correct data settings information 5 Affix new data badge 6 Replace in reverse order ELECTRICAL CONNECTIONS IMPORTANT Electricity supply must be as specified in clause sect 4 10 When controls external to the appliance are required design of the external electrical circuits should be undertaken by a competent person In accordance with the IEE wiring regulations 4 TERMINATION TO DRAIN GULLY Boiler 5 18 5 19 T External wall From this point P must be 40 mm min Open end of pipe direct into gulley below grating bul above water level It is essent
16. 5 18 INSTALLATION INSTRUCTIONS FOR CONCENTRIC 80 125 FLUE SYSTEM L The vertical 80 125 flue kit is intended for use where a horizontal 60 100 flue outlet is not possible or desired TTT LN The vertical flue can be installed on either a flat roof a pitched roof maximum pitch 60 Where a straight vertical flue is not possible or desired an offset vertical flue can be used in conjunction with a side horizontal flue extension piece and an inline 135 990 flue bend fig 27 IMPORTANT See fig 6 for terminal clearances Fig 27 m To overcome low roof or below ground IMPORTANT NOTICE basement When using our vertical flue kit the 125 mm x 100 reducer is supplied complete with the vertical terminal simply remove this and fix it into the straight flue header which must be fitted on the top of the boiler L L 23 5m Max playa EH B Vertical standard Vertical standard gt Vertical standard Vertical standard flue kit 1100mm flue kit 1100mm flue kit 1100mm flue kit 1100mm Must NOT be shortened Must NOT be shortened Must NOT be shortened Must NOT be shortened Collar
17. FILLING THE HOT WATER SYSTEM Close all hot water draw off taps Open the cold water inlet cock Slowly open each draw off tap until clear water is discharged LIGHTING THE BOILER Before lighting the boiler make sure that the heating circuit flow and return valves are open and also that the cold water input cock is open If external controls are installed E g time clock and thermostat make sure that they are calling for heat Select winter function the winter icon in digital display will be flashing item 3 fig 2 To select the minimum heating temperature press the radiator button IMPORTANT Before lighting the boiler select the minimum central heating temperature This must be left at minimum for approx 5 mins to purge air safely from the boiler imi q H Drain point 6 8 6 9 To select the minimum heating temperature press the radiator button Press arrow up and arrow down buttons to adjust The digital display shows the current set temperature in central heating After a few seconds the digital display shows the central heating temperature in demand C H icon flashing item 3 fig 2 The fan starts and after a few seconds or so the digital led display will show that the ignition has commenced NOTES Put the di
18. Dwetervavebypass Fomisso Dweterwvemoerdip zz 510 OO 9 tgasket cunoroeso __ Gesveveiltppe 5 mus Fewpe as sovnoro GH fewanireumsensors omnee ar ommsowo Primary heat exchanger Oing as romisoso Primary heat exchangercip as Overestthemostst gemens oo viso Manaren s ruenoro __ Flexible condensing pipe az __ Coens 251500 Condensing trap pipe hose camp 1222 russo O as 25150 __ Condensing trap hose damp 205 __ Wtgevavegaet s vaisoso Gmwwe 1 Awgesmerncion 8 9 40 ORI150050 Air gas mixer junction O ring el Description Part No Air gas mixer junction clip WH 90 air gas mixer 42 1 WH 80 air gas mixer Air gas mixer fan O ring Fan Fan burner gasket Sensing electrode Spark electrode Sensing spark electrode gasket WH 90 burner gasket 49 1 WH 80 burner gasket WH 80 burner 50 1 WH 90 burner Flue flange FLA110052 Flue flange gasket Flue manifold washer GUA130050 Temperature flue sensor Spark igniter Fl
19. NOMINAL HEAT OUTPUT CONDENSING MINIMUM HEAT OUTPUT MINIMUM HEAT OUTPUT CONDENSING GAS RATE AFTER 10 MINUTES INLET PRESSURE FAN SPEED 5400 rpm 180 Hz C H min 1650 rpm 55 Hz Mixer orifice fucsia ELECTRICAL SUPPLY POWER CONSUMPTION EXTERNAL FUSE RATING INTERNAL FUSE DRY WEIGHT WATER CONTENT WATER CONTENT GAS SUPPLY CONNECTION FLOW CONNECTION C H RETURN CONNECTION C H INLET CONNECTION D H W OUTLET CONNECTION D H W SAFETY DISCHARGE C H CONDENSATION DRAIN 24 5 kW 6 8 kW 24 1 kW 26 5 kW 6 7 kW 7 4 kW max 2 5 m h min 0 7 m3 h 20 mbar Combustion CO G20 9 0 0 4 0 5 Case ON G20 8 8 0 4 0 5 Case OFF 230 V 50 HZ 160 W F1 3 15A 20 10 BS 4265 39 5 kg 2 0 litre 0 5 litre 15 mm compression isolating valve 22 mm compression isolating valve 22 mm compression isolating valve 15 mm compression isolating valve 15 mm compression valve 15 mm copper pipe 3 4 21 5 mm push fit over flow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM MAX PRESSURE PHS MINIMUM WORKING PRESSURE 2 5 bar 0 5 bar 8 LITRES EXPANSION VESSEL PRE CHARGE PRESSURE 0 5 bar CENTRAL HEATING OPERATING TEMPERATURE __ MAX 80 C 45 C DESIGN FLOW RATE 1383 20 C RISE MINIMUM FLOW RATE 503 l min D H W FLOW RATE 30 rise D H W FLOW RATE 35 rise 13 4 l min 11 5 l min D H W FLOW RATE
20. Check Replace flue sensor RESET THE BOILER Does boiler go off before set point Check if the system has been purge of air Check Replace Automatic air vent Push the Reset button on Digital Display No and check LCD if illuminate NOTE See Section 10 page 51 for LED DISPLAY CODE FAULT FINDING DOMESTIC HOT WATER Before continuing it may be necessary to see Central Heating Fault Finding Sect 9 All gas supply cocks are open and the gas supply has been purged of air The heating system pressure is at least 1 bar min to 1 5 bar Max Main Switch on Select Summer Fig 50 item 1A Domestic Hot Water control knob to maximum Open Domestic hot tap close to the appliance Ensure Domestic Hot Water flow is min of 3 l min Check filters are clean Check Microswitch Is low pressure on shunt valve DOSE DE TCD in the system being operate on digital display mechanically illuminate Check Replace Yes diverter valve Re pressure the Check Replace System diverter valve Does the burner led illuminate on DHW SENSOR SEQUENCE CODE control panel I OS displayed Check Replace DHW sensor and cables HEATING SENSOR SEQUENCE CODE Check Replace heating sensor Is 12 displayed LOW WATER PRESSURE SWITCH splayed SEQUENCE CODE Check Replace Low water pressure switch Check system pressure Is 30 displayed FLUE TEMPERATURE SEQUENCE CODE
21. FILLING THE HOT WATER SYSTEM Close all hot water draw off taps Open the cold water inlet cock Slowly open each draw off tap until clear water is discharged LIGHTING THE BOILER Before lighting the boiler make sure that the heating circuit flow and return valves are open and also that the cold water input cock is open external controls are installed e g timeclock and thermostat make sure that they call for heat Push Summer Winter switch Fig 33 to Winter IMPORTANT Before switching on the boiler POWER SWITCH FOR THE FIRST TIME when commissioning turn the heating control knob Fig 33 DOWN TO ITS MINIMUM setting leaving it at minimum for approx 5 mins to purge air safely from the boiler heat exchanger e Gasket Drain point Drain point cap 6 8 6 9 34 Turn control knob Fig 33 down to its minimum setting Push the power main switch to on Fig 33 The digital display will show water set point temperature in central heating The fan starts and after a second or so the digital led display will show that the ignition has commenced NOTES It maybe necessary to reset the Digital Timer on boiler if fitted to start Put the timer to on position Fig 33 The ignition control will automatically have three attempts but initially this may be due to air in the gas supply line If the burner fails to light the digital led display and fan will stop
22. Flashing inlet and exhaust terminals must never be installed on opposite walls of the building PrEN 483 If the flue terminates less than 2 above a balcony above the ground or above a flat roof to which people have access then a suitable terminal guard must be fitted Fit only recommended flue terminal guard by securing concentrically around terminal with screws L 11 39 5m plus Terminal 5 8 2 Exhaust suction system with concentric pipes for flat or sloping roofs Extensions with two separate pipes Fig 25 Maximum distance T L 21 21 42 metre Terminal Minimum distance L 0 5 0 5 1metre Terminal Exhaust terminal must not be cut NOTE If bends are used in the exhaust flue then horizontal sections must be avoided and there must be a 1 5 slope towards the boiler 25 mm fall per metre IMPORTANT Please lubricate the internal part of the seals before Exhaust suction system with two separate rated 80 dia being fitted Pipes exhaust on flat or sloping roof suction from vertical wall Fig 26 Maximum distance D L1 39 5 metre Terminal Minimum total length 2 metre NOTE Exhaust
23. Remove front panel fig 39 Remove the instrument panel sect Fig 54 8 24 Detach all connectors from control board unscrew the four screws and lift up Replace in reverse order fig 55 Panel control box 4 TO REMOVE REPLACE DIGITAL DISPLAY BOARD Control board Remove the front panel fig 39 Remove the instrument panel 8 24 Fig 55 Detach the connectors and unscrew the four screws Replace in reverse order Unscrew the four screws and lift up 9 FAULT FINDING CENTRAL HEATING Before trying to operate the boiler make sure that all gas supply cocks are open and the gas supply has been purged of air The heating system pressure is at least 1 bar min to 1 5 bar max select winter position on the digital display and set the central heating temperature to maximum sect 1 5 Ensure external controls are calling for heat room thermostat digital clock and check the following appliance operations Does the display Check replace external fuse illuminate control beard and check incoming supply yes Does the display Wait a few minutes for the power supply show CLOW to charge the display enough to allow all the functions to operate Does the display
24. Supply pipe Double Return pipe Temporary connection check valve 4 17 SIZING OF ADDITIONAL EXPANSION VESSEL TABLE 4 Deduct from the value given in the table the 7 litre vessel supplied Safety 3 0 valve setting bar Vessel charge pressure bar Initial system pressure bar Total water content of system Litres For system volumes other than those given above multiply the system volume by the factor across Note This pressure can be increased up to 1 5 bar to suit high static head situations If the capacity of the central heating system BS 7593 2006 details the steps necessary should exceed 110 Litres an additional to clean domestic central heating system vessel should be installed on the return to the Also check pipework and renew any combination boiler from the heating system corroded pipework or fittings Valve glands fig 7 Guidance on vessel sizing is given must be repacked or replaced wherever see table 4 T necessary and any defective controls Reference should be made to British Gas exchanged Publications Draining taps should be at least 1 2 in BSP nominal size and be in accordance Debris from the system can damage the with BS 2879 boiler and reduce the efficiency Failure to comply with the guidelines for the use INSTALLATION TO AN EXISTING CENTRAL of water treatment with the appliance will HEATING SYSTEM invalidate the appliance guarantee and E contravene the Building Regulati
25. TABLE 3 A GAS SUPPLY CONNECTION 15 mm compression isolating valve FLOW CONNECTION C H 22 mm compression isolating valve RETURN CONNECTION C H 22 mm compression isolating valve INLET CONNECTION D H W 15 mm compression isolating valve OUTLET CONNECTION D H W 15 mm compression valve SAFETY DISCHARGE C H 15 mm copper pipe CONDENSATION DRAIN 3 4 21 5 mm push fit over flow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C H MAX PRESSURE PHS 2 5 bar MINIMUM WORKING PRESSURE 0 5 bar 7 LITRES EXPANSION VESSEL PRE CHARGE PRESSURE 0 5 bar CENTRAL HEATING OPERATING TEMPERATURE 80 C 35 DESIGN FLOW RATE 1383 20 C RISE MINIMUM FLOW RATE C H 350 D H W FLOW RATE 30 rise 11 9 l min D H W FLOW RATE 35 rise 10 2 l min D H W FLOW RATE 40 rise 8 9 l min 10 C inlet temperature D H W TEMPERATURE Max 60 C min 35 FAN SPEED D H W Max 4800 rpm 160 Hz min 1300 rpm 43 Hz Qmw Input Net Max 25 4 kW min 3 7 kW D H W PRESSURE PMW Max 6 5 bar D H W PRESSURE PMW min 0 5 bar D H W MINIMUM FLOW RATE 2 5 l min FLUE OUTLET NOM DIAMETER 100 mm specially supplied with boilers If required DESTINATION GB IE ES IT PT amp GR CATEGORY llzuse FLUE TYPE C13 Cas NO 5 SEDBUK IP X4 D 3 4 TECHNICAL DATA WH 80 T LPG G 31 NOMINAL HEAT INPUT NET QMS 20 0 kW MINIMUM HEAT INPUT NET 3 7 kW NOMINAL HEAT OUTPUT 1
26. and automatic air vent for any water leaks Rectify if necessary Examine and remove loose debris from the combustion chamber using a soft brush and vacuum cleaner Carefully flush by spraying water any remaining debris through the condensate trap Ensure the water is kept away from electrical components Inspect the siphonic condensate trap for a blockage Remove the cap at the base of the condensate trap Remove any solid found Remove the float to clean it Any deposits should be flushed out Reassemble and refit the condensing trap When refitting the cap ensure that a watertight seal is achieved but do not use excessive force Examine the spark and sensing electrodes for any mechanical damage Clean away any debris and check the spark and sensing gap Examine flue duct and flue manifold and ensure that there is no obstruction Examine the gasket at the entry into the flue manifold It is essential that a good seal is made at the outlet to the flue manifold renew this gasket if there is any sign of damage or deterioration SECTION 8 8 1 REPLACEMENT OF PARTS GENERAL Replacement of parts must be carried out by a competent person Before replacing any parts the boiler should be isolated from the mains electric supply and the gas should be turned off at the service cock on the boiler After replacing any parts always test for gas soundness and if necessary carry out functional test of the con
27. and the display will show the lockout code If necessary push the boiler Reset button Fig 33 and the boiler will restart automatically After the boiler has lit allow to warm at minimum temperature setting to purge any air from the system Once the system has been purged of air turn the control knob to the desired position With leak detection fluid test for gas tightness of all gas components and joints See paragraph 6 14 for regulating the heating circuit control knob CHECK THE GAS PRESSURE Check the gas mains pressure at the gas valve inlet pressure test Fig 34 with boiler operating Check with the Local Gas supplier if the pressure differs significantly from 20 mbar G20 natural gas 37 mbar G31 propane and 29 mbar G30 butane IMPORTANT the Gas Valve Throttle adjuster is required to be sealed with tamper proof paint after adiustment fig 34 COMBUSTION CHECK Check gas carrying components along with the combustion of the appliance which should be checked as follows Remove the front panel of the case Ensure the boiler and external controls are calling for heat Turn on electrical supply Open the Hot water tap at maximum flow rate Wait at least five minutes or until the unit has reached its operating temperature ELECTRODES POSITION Fig 36 Sensor electrode Unscrew the test sample screw on the boiler elbow bend Fig 10 item 60 Measure the level of CO Check the reading against the
28. corresponding value in sect 3 TECHNICAL DATA If adjustment proves necessary then proceed as follows IMPORTANT Any adjustment to the gas valve should only be carried out by a qualified person Refer to tables 1 A 1 B 1 C and 1 D section 3 adjust the maximum level of CO by turning the Throttle allen screw 2 5 mm on the gas valve Fig 34 Anti clockwise to increase CO Clockwise to decrease CO After any new regulation wait to stabilise about one minute Replace the sample point screw on the flue manifold Fig 10 item 60 Replace the front panel of the case IMPORTANT do not insert analyser probe into the sample point immediately or for long periods This will prevent saturation of the analyser During the calibration function the combustion ratio may increase for short time while the boiler performance is optimised The person carryng out a combustion measurement should have been asessed as competent in the use of a flue gas analyser and be able to interpret of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturer s requirements Ignition electrode ATTENTION IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED
29. in the same way as domestic hot water mode As the heating sensor reaches temperature the fan speed modulates to maintain the temperature set on the display panel When starting the fan will always start at the set point speed On the control panel are mounted two potentiometers thermostats these control the temperature One is for domestic hot water and the other for heating The boiler is fitted with an anti cycling device on the control board This delays the boiler from re firing within 10 minutes If the heating temperature goes 20 C below the set point the burner restarts immediately The domestic hot water will always take priority and is unaffected by the anti cycling device GENERAL FUNCTION Central Heating Mode The potentiometer fitted on the instrument panel permits regulation of the boiler to partial heating requirements between maximum and minimum settings Air and gas are drawn by the fan for combustion The fan also forces exhaust gas through the flue to the outside this creates a lesser pressure in the sealed combustion chamber thus sucking in combustion air through the inlet duct The boiler water temperature is automatically controlled by a built in thermostat Interior space temperature is set by the room thermostat to be installed in the heating system The boiler already carries connection terminals for this thermostat as well as for a timeclock The burner continues to operate until i
30. min fan speed R19 DHW max fan speed Clockwise increase fan speed Anticlockwise decrease fan speed KEEP HOT Fig 38 The boiler comes with an optional keep hot facility This can be switched on by placing the jumper JP14 on the circuit board over the pins or remove this to cancel then reset the boiler This will result in the boiler at any time periodically firing to keep the water within the boiler up to temperature to reduce the time delay of hot water The operation of the boiler including the use and adjustment of ALL system controls which should be fully explained to the Householder This then ensures the greatest possible fuel economy consistent with household requirements of both heating and hot water consumptions Advise the User of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frost conditions delivered to any hot draw off point Explain the function and the use of the boiler the summer winter switch the ON OFF switch and the reset of the digital display The boiler comes set in Central heating at Explain and demonstrate the function the MID RANGE of its output of temperature controls neon lights radiator valves etc for the economic use of the system If an optional time clock is fitted then draw attention to the time clock User s Instructions and hand them to the Householder Stre
31. push fit over flow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C H MAX PRESSURE PHS 2 5 bar MINIMUM WORKING PRESSURE 0 5 bar 7 LITRES EXPANSION VESSEL PRE CHARGE PRESSURE 0 5 bar CENTRAL HEATING OPERATING TEMPERATURE 80 C 35 DESIGN FLOW RATE 1811 I h 20 C RISE MINIMUM FLOW RATE C H 350 D H W FLOW RATE 30 rise 14 0 l min D H W FLOW RATE 35 rise 12 0 l min D H W FLOW RATE 40 rise 10 5 l min 10 inlet temperature D H W TEMPERATURE Max 60 C min 35 FAN SPEED D H W Max 4800 rpm 160 Hz min 1300 rpm 43 Hz Qmw Input Net Max 30 1 kW min 4 1 kW D H W PRESSURE PMW Max 6 5 bar D H W PRESSURE PMW min 0 5 bar D H W MINIMUM FLOW RATE 2 5 l min FLUE OUTLET NOM DIAMETER 100 mm specially supplied with boilers If required DESTINATION GB IE ES IT PT amp GR CATEGORY llzuse FLUE TYPE C13 Cas NO 5 SEDBUK IP X4 D 3 3 TECHNICAL DATA TABLE 3 D WH 90 T LPG 31 2 NOMINAL HEAT INPUT NET QMS 24 5 kW MINIMUM HEAT INPUT NET 4 1 kW NOMINAL HEAT OUTPUT 23 8 kW NOMINAL HEAT OUTPUT CONDENSING 26 2 kW MINIMUM HEAT OUTPUT 4 0 kW MINIMUM HEAT OUTPUT CONDENSING 4 4 kW GAS RATE max G31 1 0 m h AFTER 10 MINUTES min 0 16 m3 h INLET PRESSURE G31 37 mbar G30 28 30 FAN SPEED C H Max 4200 rpm 140 Hz Combustion CO 10 5 0 5 0 5 Case ON min 1300 rpm 43Hz 10 5 4 0 5 0 5 Case OFF ELE
32. 1 B SECTION 3 TECHNICAL DATA TABLE 1 C WH 130 T NATURAL GAS 20 12 gt NOMINAL HEAT INPUT NET QMS MINIMUM HEAT INPUT NET NOMINAL HEAT OUTPUT NOMINAL HEAT OUTPUT CONDENSING MINIMUM HEAT OUTPUT MINIMUM HEAT OUTPUT CONDENSING GAS RATE AFTER 10 MINUTES INLET PRESSURE FAN SPEED 5400 rpm 180 Hz C H min 1650 rpm 55 Hz Mixer orifice red ELECTRICAL SUPPLY POWER CONSUMPTION EXTERNAL FUSE RATING INTERNAL FUSE DRY WEIGHT WATER CONTENT WATER CONTENT GAS SUPPLY CONNECTION FLOW CONNECTION C H RETURN CONNECTION C H INLET CONNECTION D H W OUTLET CONNECTION D H W SAFETY DISCHARGE C H CONDENSATION DRAIN 29 6 kW 7 8 kW 29 0 kW 32 0 kW 7 6 kW 8 4 kW max 3 4m h min 0 85 20 mbar Combustion CO G20 9 0 0 4 0 5 Case ON G20 8 8 0 4 0 5 Case OFF 230 50 HZ 160 W 3A F1 3 15A 20mm to BS 4265 42 5 kg 2 0 litre 0 5 litre 15 mm compression isolating valve 22 mm compression isolating valve 22 mm compression isolating valve 15 mm compression isolating valve 15 mm compression valve 15 mm copper pipe 3 4 21 5 mm push fit over flow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM MAX PRESSURE PHS MINIMUM WORKING PRESSURE 2 5 bar 0 5 bar 8 LITRES EXPANSION VESSEL PRE CHARGE PRESSURE 0 5 bar CENTRAL HEATING OPERATING TEMPERATURE __ 80 C 45 C DESIGN F
33. 16 17 18 FOR APPLIANCE CLEARANCES SEE SECT 4 4 AND SECT 4 10 Use adhesive tape to attach the template to the wall making sure that the centre line is vertical and that the clearance distance is no less than that shown in fig 13 Mark the two holes for the top fixing bolts to fix the boiler on the wall as well as the centre of the flue duct Detach the template from the wall Use a 10 mm dia drill to make the 2 holes Insert the plastic expansion plugs Cut or core drill a 105 mm dia hole for inserting the flue duct Fit the elbow header into the flue flange on the top of the boiler positioning it towards the required direction fig 13 Important Make sure that the dia 60 mm on the elbow header is inserted fully into the flue manifold and the flue manifold rubber seal is correctly fitted Fig 17 item 65 If using the horizontal flue duct and it is too long it can be shortened Should it be necessary to cut the flue always cut on right angles and ensure the cut is de burred Note Add 30 mm to overall flue length to allow for terminal wall cover fig 10 item 127 Insert the flue assembly into the wall Lift the boiler on the wall locating onto the top two fixing bolts Tighten the two bolts using a spanner to secure to the wall Working above the boiler pull the flue exhaust duct towards the boiler in order to engage tube fig 18 item 61 into its header Position flue into elbow header and p
34. 19 2 to 8 19 3 Detach the connectors from control board Detach the connectors from the board Rotate and pull 8 23 3 Detach the Digital Display board from panel instruments by unscrewing the four securing screws Replace in reverse order TO REMOVE REPLACE THE MAIN SWITCH Fig 33 Remove front casing sect 8 1 4 and push the retaining latches and remove the instrument panel Pull left side and remove Pull off the switch knob Remove the switch out from the instrument panel by pressing the clamp springs Detach the wires that connect to the switch make sure that these wires are later reconnected to the same poles Replace in reverse order 8 25 4 Unscrew and remove UE gt 6 Sl Mu TO CLEAN AND REMOVE REPLACE CONDENSING TRAP Fig 60 Remove front casing sect 8 1 4 Remove the bottom panel and the left side panel Drop down control box sec 8 20 Remove the securing clip and pull out the plastic pipe that connect the condensing trap at the heat exchanger Unscrew the nut that fasten the condensing trap to the depression chamber and remove it Replace in reverse order d Inlet plastic flexible pipe Securing clip 1 2 brass nut Head cap mm Siphon adapter E Seal Condensing W trap unit A Seal 3 Cap R
35. 2 0 5 Case OFF Mixer orifice red ELECTRICAL SUPPLY 230 V 50 HZ POWER CONSUMPTION 160 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 3 15A 20 mm to BS 4265 DRY WEIGHT 42 5 kg WATER CONTENT C H 2 0 litre WATER CONTENT 0 5 litre GAS SUPPLY CONNECTION 15 mm compression isolating valve FLOW CONNECTION C H 22 mm compression isolating valve RETURN CONNECTION C H 22 mm compression isolating valve INLET CONNECTION D H W 15 mm compression isolating valve OUTLET CONNECTION D H W 15 mm compression valve SAFETY DISCHARGE C H 15 mm copper pipe CONDENSATION DRAIN 3 4 21 5 mm push fit over flow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C H MAX PRESSURE PHS 2 5 bar MINIMUM WORKING PRESSURE 0 5 bar 8 LITRES EXPANSION VESSEL PRE CHARGE PRESSURE 0 5 bar CENTRAL HEATING OPERATING TEMPERATURE 80 45 C DESIGN FLOW RATE 1811 I h 20 C RISE MINIMUM FLOW RATE C H 503 l min D H W FLOW RATE 30 rise 17 0 l min D H W FLOW RATE 35 rise 14 5 l min D H W FLOW RATE 40 rise 12 7 l min 10 C inlet temperature D H W TEMPERATURE Max 60 C min 40 FAN SPEED D H W 6300 rpm 210 Hz 1650 rpm 55 Hz Qmw Input Net Max 36 4 kW min 7 8 kW D H W PRESSURE PMW Max 10 bar 147 p s i D H W PRESSURE PMW min 0 8 bar 118 p s i To obtain heat input 1 2 bar D H W MINIMUM FLOW RATE 3 l min FLUE OUTLET NOM DIAMETER 100 mm specially supplied w
36. 2949 yBiy 00 SI Y29049 Hulsues pue xy1eds yooyuD 2949 JOU SI ejesuepuoo 29420 eunsseJd sef YOOYD 10 T3009 35Nano3as peeds MHA 6 1 peeds ue uiu OLY peeds H2 6 4 Overheat thermostat jebi B 9JIUM M JOIOIA pelu uoeJD 6 KeJD 16 5 s DHW potentiometer Main ON OFF switch 3 way DHW gt lt a Umoq 1 Jayuby q Dupueds eniq jeuondo 20 oeuur 10 yuid d jeuondo wooy 6I 10105 eJnsseJd pue i ME copa Ej 0 d x Jowod eur eqoud OLN 9 a TD Osho eqoid OLN HO zar egoud OLN MHA zx T SECTION10 ELECTRICAL SYSTEM DIAGRAM Hall effect PWM signal 24 VDC SECTION 11 SPARE PARTS
37. 40 rise 10 1 l min 10 inlet temperature D H W TEMPERATURE FAN SPEED D H W Max 60 C Max 6300 rpm 210 Hz min 40 min 1650 rpm 55 Hz Qmw Input Net Max 29 0 kW min 6 8 kW D H W PRESSURE PMW D H W PRESSURE PMW D H W MINIMUM FLOW RATE Max 10 bar 147 p s i min 0 8 bar 118 p s i l min To obtain heat input 1 2 bar FLUE OUTLET NOM DIAMETER 100 mm specially supplied with boilers If required DESTINATION AT DK Fl SE GR DESTINATION GB IE CH ES IT PT amp GR FLUE TYPE C13 C33 Css CATEGORY 2 CATEGORY 112 NO 5 SEDBUK SECTION 3 TECHNICAL DATA WH 100 T LPG G 30 G 31 Is IIzus NOMINAL HEAT INPUT NET QMS 24 5 kW MINIMUM HEAT INPUT NET 6 8 kW NOMINAL HEAT OUTPUT 24 1 kW NOMINAL HEAT OUTPUT CONDENSING 26 5 kW MINIMUM HEAT OUTPUT 6 7 kW MINIMUM HEAT OUTPUT CONDENSING 7 4 kW GAS RATE max 931 0 9 G30 0 7 m h AFTER 10 MINUTES min 0 4 m h 0 3 m h INLET PRESSURE G31 37 mbar G30 28 30 mbar FAN SPEED C H Max 4800 rpm 160 Hz Combusiton CO 631 10 2 0 2 0 5 Case ON min 1650 rpm 55 Hz G30 11 0 0 2 0 5 Case ON FAN SPEED Max 4800 rpm 160 Hz Combusiton CO G31 9 9 0 2 0 5 Case OFF min 1650 rpm 55Hz G30 10 8 0 2 0 5 Case OFF Mixer orifice fucsia ELECTRICAL SUPPLY 230 V 50 HZ POWER CONSUMPTION 160 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 3 15A 20 mm to BS 4265 DRY WEIGHT 39
38. 8 Press to show the boiler values 2 Press to reset the appliance if ever an error Use the arrow up and arrow down buttons to select code is displayed the follows info 3 4 Temperature and function mode selectors PBAR water pressure Press the arrow up or the arrow down to SFAN speed fan the display shows digits increase or decrease the heating or domestic e g 500 5000 rpm hot water outlet temperature when the digital TFLOW flow temperature display is in hot water or domestic set point TRET return temperature temperature TDHW domestic hot water temperature Press also to show the boiler values or to PWR power of modulation show the options program when the digital display is in menu setting Press 3 seconds to enter into menu Use the arrow up or arrow down buttons to select 5 Press to set the Central Heating the following options Temperature required when in winter mode TIME time clock version only It is possible to Press the arrow up or the arrow down buttons set the time and the current day Monday 1 to increase or decrease the temperature Tuesday 2 Wednesday 3 Thursday 4 Friday 5 Saturday 6 Sunday 7 see section 1 7 6 Press to set the Domestic Hot Water PTMR only time clock version Is possible to Temperature required set the time clock see section 1 8 Press the arrow up or the arrow down buttons BOIL Is possible to set the boiler parameters to increase or decrease the temperature C
39. Description Starting at the appliance end assemble the extension duct sections making each inner and outer flue joint by inserting the spigot end into the socket end of the next tube making sure the seal rings are correctly located Fig 23 Make sure that the entire flue is adequately supported Use at least one bracket for each extension used Ensure that all inner flue connections have a good fit seal and that the space clips in each extension are correctly positioned 59 PR5094110A 60 100 PRFE PR45FBI PR9OFBI PR5023016 PR5023016 TER110200 TABLE 4 45 bend 60 100 90 Elbow bend 60 100 Horizontal terminal 60 100 Horizontal flue kit Vertical flue Terminal 1 ___ Combi ridge i ___ Combi ridge Straight flue header sample point Flue Extension 60 100 L1000 Combi ridge a C gt CD C2 Boiler KEY 56 Flue adapter 58 Header gasket 59 Rubber seal 60 60 Fumes sample point 63 Flue extension Straight Flue L 12 0 m Max plus Combi ridge Offset Flue L 12m plus 2 bend 90 and Combi ridge Offset Flue 11 m
40. H max fan speed D H W max fan speed Keep hot 0 disabled and 1 enabled C H High Low temperature 1 high 2 low 1 5 DIGITAL DISPLAY Water pressure 2 0 bar 1 5 bar U 1 0 bar 0 5 bar KEY 1 Day indicator time clock version only 1 Monday 2 Tuesday 3 Wednesday 8 4 Thursday Dal day Heat input Ju 6 Saturday 7 2 Time time clock version only 3 Central Heating when the appliance is in central heating mode icon 3 will be 7 ON OFF When the appliance is flashing ON icon 7 is displayed 4 Auto time clock version only when the 8 Modulation flame level When the burner is lit 3 digital clock is in automatic function icon 4 different levels on icon 8 are displayed is displayed 9 Day function time clock version only 5 Water pressure Shows the current 10 Temperature pressure in the system 11 Anomaly Lock out Test function 6 Manual When the digital timer is set to 12 Domestic hot water when the appliance is in manual icon 6 is displayed in this mode the domestic hot water mode the icon will flash central heating is on permanently 1 6 BOILER VALUE 1 7 TIME time clock version only It is possible to show the boiler value SETTING THE TIME AND DAY time clock Press P button to show the boiler value version only Use the arrow up and the arrow down buttons item 3 and 4 fig 1 to show the 1 Press and hold the
41. INLET PRESSURE ensure it operates at its various setting Close the draw off tap still further The Set up the boiler to operate at maximum rate burner should stop when the rate falls by opening the hot tap to maximum flow below about 2 8 litres min 0 61 gals min With the boiler operating at the maximum rate check the operational dynamic working gas pressure test complies with the requirements Ensure that this inlet pressure can be obtained with all other gas appliances in the property working 6 12 2 Put the appliance in summer position with the summer winter switch Fig 33 Open a domestic hot water tap preferably the bath tap Ensure cold water inlet stopcock is open and the D H W control knob Fig 33 is set at maximum Digital display shows water temperature in demand led on If the boiler does not light check that the water flow rate is above the min required to operate the differential pressure 2 8 Lts min 0 61 gals min 6 12 3 CHECKING MAX MIN FAN SPEED see tables 5 A and 5 B 6 12 4 To check max fan speed place the jumper on JP16 and select the winter switch in winter position DHW tap open See sect 6 14 1 and fig 39 To check min fan speed place the jumper on JP16 and select the summer winter switch in summer position DHW tap open See sect 6 14 1 and fig 39 This can be checked using a frequency meter JP2 IMPORTANT DO NOT ADJUST THE MINIMUM SET POTEN
42. P button for 4 seconds following info 2 Press the up and down arrows to select TIME and then press the enter button PBAR water pressure 3 Press the up and down arrows to select the SFAN speed fan current hour 24h Then press the enter TFlow flow temperature button TRet return temperature Press the up and down arrows to select the TDHW domestic hot water temperature current minute and then press the enter PWR power of modulation button Press the up and down arrows to select the current day 1 Mon 2 Tue etc and then press the enter button The time is now set 1 8 PROGRAMMING THE HEATING TIMES time clock version only The appliance incorporates a digital clock Once the times are set press the P button and programmed with a default heating pattern this will return to the main screen see table 1 however this can be modified to suit individual needs NB If setting the times in a group the days in the group will all be the same however days To change the programmed times not in this group will remain at the default time For example setting Mon Sat will change all 1 Press and hold the P button for 4 seconds these days but Sunday will remain the same as 2 Press the up and down arrows to select table one unless changed individually TMR and then press the enter button 3 Press the up and down arrows to select the The programmed times will only be activated individual day you wish to se
43. Show the user the location of the filling valve and how to top up the system pressure correctly Explain the operation of the boiler including the use and adjustment of ALL system controls which should be fully explained to the Householder This will ensure the optimum fuel economy for the household requirements of both heating and hot water consumption Advise the User of the precautions rpmx1000 TABLE 11 A Range rating regulation of Central Heating C H regulations Heat input kW Fan speed rpm Maximum setting Minimum setting WH 80 WH 90 WH 80 WH 90 TABLE 11 B Minimum setting Range rating regulation of Domestic Hot Water D H W regulations Heat input kW Fan speed rpm WH 80 WH 90 WH 80 WH 90 1300 1300 RATIO BETWEEN FAN SPEED He AND HEAT INPUT 66 220 60 200 Max 54 180 48 160 42 140 36 120 30 100 24 80 18 60 12 40 minimum 6 Fig 38 20 10 0 27 8 40 9 546 68 2 81 9 95 5 109 2 122 8 Btu h x 1000 SS oS 4 8 12 16 20 24 28 32 36 Heat Input G20 G30 631 kW necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frost conditions Explain the function and the use of the boiler the summer winter button the ON OFF switch and the reset of the digital
44. Website www ravenheat co uk E mail sales ravenheat co uk Ravenheat reserves the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet COD 0017LIB13005 0 05 2012 55 SECTION 12 BENCHMARCK COMMISSIONING CHECKLIST DETAILS Boiler Page Make and model Appliance serial no on data badge Controls Auto by pass Boiler interlock For all boilers Flushing to BS7593 Inhibitor Central heating mode Heat input NOTE TO THE INSTALLER COMPLETE THE BENCHMARK COMMISSIONING CHECKLIST AND LEAVE THESE INSTRUCTIONS WITH APPLIANCE Burner operating pressure Central operating flow temp Central operating return temp For combination boilers only Scale red cer ie re eerte ed Hot water mode Max operating burner pressure measure and record Max operating water pressure measure and record Cold water inlet temp measure and record Hot water temp measure and record Water flow rate at max setting measure and record For condensing boiler only Condensate drain For all boilers complete sign amp hand over customer THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS For assistance see The White Boiler Company technical helpline telephone 0113 252 7007 fax 0113 238 0229 e mail sales ravenheat co uk Code Of Practice For the installati
45. and combustion ratio check see opposite page before proceeding to the Check CO level and combustion ratio at maximum rate stage below flooding of sensor Verify flue integrity Analyser readings indicate that combustion on products and inlet air must be mixing Further investigation of the flue is therefore required Check that flue components are assembled fixed and supported as per instructions Check that flue and flue terminal are not obstructed Oz more than or equal to 20 6 or less than or equal to 0 2 When checking the Oz the front cover must be on so the air is drawn from outside Turn off appliance and call Ravenheat Technical Helpline for advice The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with GSIUR Check that no seals e g those on the flue extensions have not been displaced during installation Rectify if necessary Is CO level less than 350 ppm AND CO COz ratio less than 0 0040 ensure this check is done with the cover off and with the cover on to check the integrity of the flue Turn off appliance and call Ravenheat Technical Helpline The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with Gas Safe
46. central heating Flue terminal position Pipework Boiler interlock control Draining tap Air release points Mains water feed central heating Permissible methods of filling Sizing of additional expansion vessel Installation to an existing central heating system Water treatment Hard water areas Domestic water Electrical supply Sections 6 9 6 10 Checking the flue system Installation Warning Delivery Unpacking of boiler Positioning of the boiler Optional extras Plume management kit Installing the appliance for rear flue outlet Installing the appliance for side flue outlet Completing horizontal flue installation Intake and exhaust terminal components In line flue bend and flue extension Vertical flue instructions Installation instructions for twin flue pipe Twin flue instructions Exhaust suction system with concentric pipes for flat or sloping roofs Extensions with two separate pipes Exhaust suction system with two Separate rated 80 dia pipes exhaust on flat or sloping roof suction from vertical wall Exhaust suction system with two separate pipes through a single vertical wall Installation instructions for 80 125 concentric flue system Assemble boiler Fitting valve pack Gas connection Central heating connection Domestic hot water connection Position of water gas connections Safety valve discharge Condensate drain connection Converting the appliance to different gas types Electri
47. connected to this appliance unless covered by these Installation and Service Instructions or as otherwise recommended by The White Boiler Company in writing If in doubt please enquire Any direct connection of a control device not approved by The White Boiler Company could invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety regulations and the above regulations NOTE The White Boiler Company WH 80 90 T combi boiler has been tested and examined by CERTIGAZ and is certified to comply with PrEN 483 and BS EN 625 Manufacturers instructions must NOT be taken in any way as overriding statutory obligations If in doubt on any point please consult The White Boiler Company LOCATION OF BOILER Siting of The White Boiler Company WH 80 90 T combi boiler must be as follows The position of installation should be within the building unless otherwise protected by a suitable enclosure Adequate space for installation servicing and air circulation around the boiler must be allowed for The White Boiler Company WH 80 90 T combi boiler must be fitted on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment The appliance may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary unless required by the local authority For electrical safety reasons there must be no access availab
48. exposed to external air It is important that the position of the terminal allows the free passage of air across it at all tirnes Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Fig 5 Note positions Due to the terminal design installation is possible with clearances less than those specified in BS 5440 Part 1 NOTE The flue must be terminated in a place not likely to cause a nuisance 4 6 2 concentric vertical flue kit is available for flueing applications up to a maximum height see table 3 page 19 For further details see vertical flue installation instructions AIR SUPPLY The following notes are intended for general guidance The room sealed fan flued boiler does not require a permanent air vent for combustion air supply Where installed in a cupboard or compartment ventilation is not required WATER CIRCULATION central heating Detailed recommendations are given in 56798 2009 5449 1990 BSEN12828 BSEN12831 BSEN14336 for smallbore and microbore central heating systems The following notes are given for general guidance PIPEWORK Copper tubing to BSEN 1057 1 2006 BSEN 1172 BSEN 1652 and BSEN 1653 is recommended for water pipes Jointing should be either with capillary soldered or with compression fittings Where possible pipes should have a gradient 4 8 4 to ensure air is carried naturally to air release points and water flows
49. falls below about 2 8 litres min 0 61 gals min KEEP HOT The boiler comes with an optional keep hot facility This can be switched on by a competent person This will result in the boiler at any time periodically firing to keep the water within the boiler up to temperature to reduce the time delay of hot water delivered to any hot draw off point Press P button item 8 fig 1 for 3 seconds to enter in menu Use arrow up and arrow down buttons item 5 and 6 fig 1 to select BOIL Press enter and reset buttons together item 1 and 2 fig 1 and enter button again Use arrow up and arrow down buttons item 3 and 4 fig 1 to select the following option Keep hot 0 disabled 1 enable Adjust if necessary C H HIGH LOW TEMPERATURE The boiler comes set in Central heating at the 80 C flow temperature It is possible to adjust the max set point to max 50 Press P button item 8 fig 1 for 3 seconds to enter in menu Use arrow up and arrow down buttons item 3 and 4 fig 1 to select BOIL Press enter and reset buttons item 1 and 8 fig 1 together and enter button again Use arrow up and arrow down buttons item 3 and 4 fig 1 to select the following option PM4 1 high temperature 2 low temperature 6 15 RANGE RATING CENTRAL HEATING OR AND DOMESTIC HOT WATER The boiler comes set in Central heating at the MID RANGE of its output The boiler ha
50. flue must slope 1 5 down towards the boiler 25 mm fall per metre Exhaust suction system with two separate Available on request from pipes through a single vertical wall Fig 27 THE WHITE BOILER COMPANY Chartist Way Morley Leeds West Yorkshire Maximum distance D L L1 37 metre ENGLAND LS27 9ET U K Minimum distance D 11 1 metre Tel 0044 0 113 252 7007 Min distance between pipe 50 mm 5 9 INSTALLATION INSTRUCTIONS FOR CONCENTRIC 80 125 FLUE SYSTEM 5 9 1 The vertical 80 125 flue kit is intended for use 7 where horizontal 60 100 flue outlet is not possible or desired The vertical flue can be used either with a flat roof or a pitched roof maximum pitch 60 Where a straight vertical flue is not possible or desired an offset vertical flue can be used in conjunction with a side horizontal flue extension piece and an inline 1357 90 flue bend Fig 28 IMPORTANT To overcome low roof or See Fig 5 for terminal clearances below ground The pressure loss see table 3 page 19 basament installations IMPORTANT NOTICE When using our vertical flue kit the 125 mm x 100 reducer is supplied complete with the vertical terminal simply remove this L L 23 5m Max and fix it into the flue o
51. handling this appliance and where applicable the pertinent parts that contain any materials that could be interpreted as being injurious to health and safety GENERAL INFORMATION GLUES AND SEALANTS exercise caution if these are still in liquid form THE WHITE BOILER COMPANY use only high quality material for production of this product in an effort to protect the environment wherever possible components should be recycled WARNING when installing the appliance care should be taken to avoid any possibility of injury when handling sheet metal parts Users instructions Sections Users guide Introduction Clearances around the appliance Operating safety checks to protect your appliance checking the system pressure Appliance status indicators Digital display Boiler value Time Programming the heating times Diagnostic General layout Operating scheme Introduction Description of control system and sequence of operation Domestic hot water mode Central heating mode General function Overall dimension Safety device Available pump head Pressure drop across appliance Technical data WH 80 T natural gas Technical data WH 80 T LPG Technical data WH 90 T natural gas Technical data WH 90 T LPG General requirements Safety Gas safety Installation and use General information Location of boiler Clearances around the appliance Important notice Gas supply Flue system Air supply Water circulation
52. mm m fall per metre of As with all flues the kits must be installed flue length taking due account of the current issue of BS 5440 parts 1 amp 2 and timber frame housing Spacing Clips DM2 is referenced to the Institute of Gas Spacing Clips are available on request should Engineers Document IGE UP 7 they be required Also note that the requirements will vary NOTE for eccentric vertical flue a 125 mm depending upon the kit being installed 5 in diameter flashing plate will be required Guidance is provided but unless otherwise stated always comply with the recommendations of the relevant codes of practice L 42 m max terminal T Max length 43 m IMPORTANT Please lubricate the internal part of the seals before fitting IMPORTANT See fig 6 for terminal clearances Vertical standard flue Kit 1100 mm Must NOT be shortened IMPORTANT NOTICE Flashing Inlet and exhaust terminals must never be installed on opposite walls of the building PrEN 483 If the flue terminates less than 2 above a balcony above the ground or above a flat roof to which people have access then a suitable terminal guard must be fitted Fit only recommended flue terminal guard by securing concentrically around terminal with screws
53. naturally to drain taps It should be ensured as far as possible that the appliance heat exchanger is not a natural collecting point for air except where providing useful heat pipes should be insulated to prevent heat loss and to avoid freezing Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors IMPORTANT A minimum length of 1 metre of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping The water through the appliance heat exchanger circuit must exceed the min 2 38 gals min 650 It h when the burner is firing It is important to ensure that this rate is achieved when sections of the system are shut off either manually or by automatic controls If the volume of circulating water is too low the boiler water temperature will rise too rapidly This could cause noise in the system or even cause the safety thermostat to trip BOILER INTERLOCK CONTROL Central heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating in compliance with Building Regulations The boiler has its own built in bypass If the system has thermostatic radiator valves on all radiators or two port valves then a bypass circuit must be fitted with an automatic bypass valve to ensure a flow of water should all valves be in the closed position See fig 6 It is important tha
54. need further advice on any points contact the Technical Services Office who would be pleased to help It is recommended that tools suitable for brass fittings are used and have a capability to accomodate hexagon sizes up to 50 mm CODES OF PRACTICE Ref Documents Detailed recommendations are containedin the following British Standard Codes of Practice BS6891 Low pressure installation pipes BS6798 Installation of gas fired hot water boilers of rated input not exceeding 70 kW BSEN12828 BSEN12831 BSEN14336 BS5546 Installation of gas hot water supplies domestic purposes 2ndFamily Gases BS5440 1 Flues for gas appliances of rated input not exceeding 70 kW BS5440 2 Ventilation for gas appliances of rated input not exceeding 70 kW BSEN 677 1998 Gas fired central heating boilers In IE the following Codes of Practice apply Standard Scope 1 5 813 Domestic gas Installations The followings standards give valauable additional information BS 5546 Installation of hot water supplies for domestic purposes BS EN 12828 Heating systems in buildings BS EN 12831 Heating systems in buildings Circulation of load BS EN 14336 Installation amp commissioning of water based heating Systems Expansion vessels and ancillary equipement for sealed water system BS 7593 Treatment of water in domestic hot water and central heating system BS 7074 Health amp Safety Document No 635 The Electricity
55. pipework and MUST be used for pipework carrying potable water ELECTRICAL SUPPLY Warning this appliance must be earthed External wiring to the appliance must be carried out by a competent person and be in accordance with the current Regulations and local regulations which apply The White Boiler Company boiler is supplied with a connection to a 230 V 50 Hz single phase supply The supply must be fused at 3 A NOTE The method of connection to the electricity supply MUST facilitate complete electrical isolation of the appliance by the use of a fused double pole isolator having a contact separation of at least 3 mm in all poles The point of connection to the electricity supply must be readily accessible and adjacent to the appliance except where the appliance is installed in a bathroom The current electrical IEE Wiring regulations must be followed in GB INSTALLATION WARNING It is MOST IMPORTANT that this appliance is installed in a HORIZONTAL POSITION with the flue air duct passing through the wall Make sure the flue is at a 1 5 incline rising from the boiler with 50 mm Flue terminal diagram states 1 5 25 mm fall back on flue fig 9 DELIVERY The appliance carton contains a Boiler fully assembled with flue adaptor b Installation instructions user instructions and Be
56. rubber seal IN LINE FLUE BEND AND FLUE EXTENSION 69 57 56 61 59 66 Securing screw 67 Flue temperature sensor 69 Air sample point 127 Terminal Rubber wall seal Yi 60 IMPORTANT Please lubricate the 128 internal part of the seals before being fitted In line Flue Bend Rubber seal 60 Air intake duct extension Flue exhaust duct extension 5 7 3 VERTICAL FLUE INSTRUCTION ONLY Fig 20 21 22 SEE FIG 5 FOR PERMISSIBLE FLUE POSITION IN LINE FLUE BEND 1000 mm MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 90 BEND OBTUSE FLUE BEND 500 mm MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 135 BEND The vertical flue kit is intended for use where a horizontal flue outlet is not possible or desired L L 8m Max The vertical flue can be used either with a flat roof or a pitched roof maximum pitch 609 Where a straight vertical flue is not possible or desired an offset vertical flue can be used in conjunction with a side horizontal flue extension piece and inline 135 90 flue bend Fig 20 IMPORTANT NOTES For greater flue length see twin flue or concentric 80 125 flue instructions Proceed with installation as detailed in section 5 low roof or up to 5 5 8 of the main Installation and Servicing below ground Instruction ignoring all references to h
57. summer position by pressing the ON OFF button item 1 fig 1 please ensure that the heating circuit is charged with water above 1 bar If the domestic hot water tap is turned on the boiler will function in the following sequence The pump starts The fan starts and sends a signal back to the ignition board that the fan is running The spark ignition system is powered which in turn commences the spark igniter to operate and light the burner At this point the ignition board opens the gas valve to light the burner When the electrode sensor senses the signal that the burner is alight the spark igniter stops The fan speed settings on the boiler increases to the maximum permissible speed over a period of 5 seconds and will remain at its maximum required power until its maximum regulated temperature is achieved and then will modulate to maintain this When the domestic hot water tap is closed the diverter valve goes back into rest mode the burner is shut down along with the fan which is also switched off Central heating mode If the appliance is in winter mode with a demand for heat to supply radiators etc with the heating circuit fully charged above 1 bar so as to operate the low water sensor device the boiler will start in the same way as domestic hot water mode As the heating sensor reaches temperature the fan speed modulates to maintain the temperature set on the display panel When starting the fan will a
58. supporting the weight of the boiler and any ancillary equipment The appliance may be installed on a combustible wall subject to the requirements of the Local Authority and Building Regulations LPG versions of this appliance shall not be installed in cellars or basements CLEARANCES AROUND THE APPLIANCE The following minimum free spaces required for installation inspection and servicing must be left around the boiler 18 inches 450 mm in front 5 inches 125 mm above 6 inches 150 mm 3 inches 75 mm min 0 2 inches 5 mm on each side 1 inch 25 mm in front when installed in a cupboard IMPORTANT NOTICE For installation into timber framed buildings please refer to the Institute of Gas Engineers Document IGE UP 7 The combination boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current 1 Wiring Regulations and Scotland the electrical provisions of the Building Regulations applicable in Scotland with respect to the installation of the combination boiler in a room or internal space containing a bath or shower Where a room sealed appliance is installed in a room containing a bath or shower any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using a bath or shower Acompartment used to enclose the combination boiler MUST be designed and constructed s
59. 0 internal part of the seals before fitting 57 Elbow header 59 Rubber seal 60 56 Rubber seal 100 60 Fumes sample point Generally speaking oils and greases are not 61 Flue exhaust duct suitable for the peroxide EPDM 62 Air intake duct therefore we suggest a correct lubrication 69 Air sample point using silicon substances for instance 127 Terminal Rubber wall seal Silikon Spray Arexons 60 a FLUE EXTENSION BOX CONTAINING Fig 11 WARNING With horizontal concentric flue the maximum 1000 mm flue extension duct as an extra cost only flue length is 8 metres duct extension can be used with when requested for side and vertical flue applications the standard flue see table 5 59 Rubber seal 60 63 Air intake duct extension 64 Flue exhaust duct extension 64 TYPE OF FLUE SYSTEM types minimum and maximum distance TABLE 5 Flue type Minimum length Maximum length m Equivalent length of 45 bend m Equivalent length of 90 bend m PLUME MANAGEMENT KIT Fig 12 FLUE EXHAUST DEFLECTION BEND Fig 12a Flue exhaust deflection bend are also available extra cost only when requested to reduce These come in both 45 and 90 degree versions pluming nuisance of condensation from These bends fit directly onto the flue exhaust terminal 60 100 horizontal concentric flue to deflect the flue gas plume in an upwa
60. 0 100 Horizontal terminal 60 100 Vertical flue Terminal Combi ridge _ Combi ridge 1 Straight flue header sample point Flue Extension 60 100 L1000 ridge Fig 21 KEY 56 Flue adapter 58 Header gasket 59 Rubber seal 60 60 Fumes sample point I 63 Flue extension 64 Flue exhaust duct extension Straight Flue 12 0 m Max plus Combi ridge Offset Flue 12 plus 2 bend 90 and Combi ridge Offset Flue L 11m Max plus 2 bend 45 and Combi ridge 65 Flue manifold rubber seal 66 Securing screw 68 Flue starter 69 Air sample point IMPORTANT Please lubricate the internal part of the seals before fitting 513 INSTALLATION INSTRUCTIONS FOR TWIN FLUE PIPE ECCENTRIC FLUE DUCT SYSTEM Vertical standard flue Kit 1100 mm Part No Description Must NOT be shortened TABLE 8 500110050 Twin flue header F80 F80 Flashing PRO110200 Straight pipe L 1000 80 gt CUR110150 90 elbow bend 80 CUR110200 45 bend 80 GRI110050 Air inlet terminal 80 GRI110100 Exhaust terminal 80 TERO060110 Vertical eccentric flue Terminal
61. 0 113 238 0229 Website www ravenheat co uk E mail sales avenheat co uk INSTALLER NOTIFICATION GUIDELINES A change to Building Regulations England and Wales requires the installer to notify when installing a heating appliance as from 1st April 2005 Install and commission this appliance to manufacturers instructions Complete the Benchmark Checklist Competent Person s Choose SELF CERTIFICATION SCHEME Buildings Regulations notification route BUILDING CONTROL Contact your relevant If you notify via Local Authority Gas Safe Register they will then notify the relevant Building Control LABC who Local Authority Building will arrange an inspection Control LABC scheme or contact a government on members behalf approved inspector LABC will record the data Gas Safe Register Engineers and will issue a log on to the engineers section certificate of compliance of the website at www gassaferegister co uk or telephone 0800 408 5577 You must ensure that the notification number issued by Gas Safe Register is written IT IS A CONDITION OF THE onto the Benchmark Checklist MANUFACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS Gas Safe Register will record the data and will send a certificate FULLY COMPLETED AND LEFT of compliance to the property WITH THE APPLIANCE HIGH EFFICENCY CONDENSING BOILER FOR CENTRAL HEATING AND DOMESTIC HOT WATER This new super high efficient turbo mo
62. 10 The terminal must not be located in a place where it is likely to cause a nuisance in cold and or humid weather as water vapour may condense on leaving the flue terminal The effect of such pluming must be considered The terminal must not be closer than 25 mm 1 inch to any combustible material for protection of combustibles refer to BS 5440 1 Where a flue terminal is installed less than 1000 mm from a plastic or painted gutter or 500 mm from painted eaves an aluminium shield 1000 mm long should be fitted to the underside of the gutter or painted surface Pluming will occur at the terminal so where possible terminal positions which could cause a nuisance should be avoided The flue must be installed in accordance with the recommendations of BS 5440 Part 1 IMPORTANT NOTES For greater flue lengths see alternative flue instructions Flue must be positioned in a place not likely to cause a nuisance from pluming IMPORTANT NOTICE If the flue terminates below a balcony above the ground above a flat roof to which people have access then a suitable terminal guard must be fitted if less than 2 meters high PRO110100 Fit only recommended FLUE TERMINAL GUARD by securing concentrically around terminal with screws Available on request from The White Boiler Company Chartists Way Morley Leeds West Yorkshire ENGLAND LS27 UK Tel 0113 252 7007 IMPORTANT The following notes are intended for gene
63. 25 mm fall per metre of the flue length Trace the centre of the flue duct hole measure distance From the corner of the wall Fig 14 measure the distance 160 mm between the centre of flue duct hole to the corner Detach the template from wall Use a 10 mm dia drill to make the 2 holes for securing hanging bracket fixing Insert the plastic expansion plugs Core drill a 105 mm dia hole in the side wall for inserting the flue duct Positioning the elbow towards the required direction on the boiler Make sure that rubber seal 60 is locate into the elbow If using horizontal flue duct and it is too long it can be shortened Should it be necessary to cut the flue always Cut equal amounts from both inner and outer pipes Note add 30 mm to overall flue length to allow for terminal rubber wall seal Fig 10 item 127 1 5 Inclined min 125mm WALL BRACKET WALL PLUG Remove the centering spring pull the flue terminal disengage inner flue duct Measure the thickness of the wall Cut the outer air duct 100 mm dia at right angles Cut the inner flue duct 60 mm dia at right angles Outer air duct and inner flue duct must be de burred Reassemble the two tubes e Recomended 268mm right only Insert the flue assembly into the wall making sure it will not interfere when fixing the boiler on the wall Lift the boiler on the wall Locate onto the wall fix
64. 379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts 1 to 4 To ensure continued efficient operation of the appliance it is necessary to carry out servicing and cleaning at regular intervals The frequency of servicing and cleaning will depend upon the particular installation conditions and usage but in general once a year is advisable WARNING Before the start of any servicing or replacement of components always isolate the electricity supply to the appliance and always turn off the appliance gas supply at the gas service cock The Data badge is positioned low on the inside left panel The following notes apply to the appliance and its controls but it should be remembered that attention must also be paid to the heating and hot water circuits with special attention to radiator valves thermostats clocks leaking hot water taps etc Where it is necessary to replace a gasket that relies on adhesive for securing this adhesive will be supplied with the gasket as a spare item In all cases prior to servicing remove the front panel of the case Operate the appliance by turning the hot water services on to a high water flow Measurement of the products of combustion can be achieved by connection of a pro
65. 5 kg WATER CONTENT 2 0 litre WATER CONTENT 0 5 litre GAS SUPPLY CONNECTION 15 mm compression isolating valve FLOW CONNECTION C H 22 mm compression isolating valve RETURN CONNECTION C H 22 mm compression isolating valve INLET CONNECTION D H W 15 mm compression isolating valve OUTLET CONNECTION D H W 15 mm compression valve SAFETY DISCHARGE C H 15 mm copper pipe CONDENSATION DRAIN 3 4 21 5 mm push fit over flow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C H MAX PRESSURE PHS 2 5 bar MINIMUM WORKING PRESSURE 0 5 bar 8 LITRES EXPANSION VESSEL PRE CHARGE PRESSURE 0 5 bar CENTRAL HEATING OPERATING TEMPERATURE 80 C 45 C DESIGN FLOW RATE 1383 20 C RISE MINIMUM FLOW RATE C H 503 l min D H W FLOW RATE 30 rise 13 4 l min D H W FLOW RATE 35 rise 11 5 l min D H W FLOW RATE 40 rise 10 1 l min 10 C inlet temperature D H W TEMPERATURE Max 60 C min 40 FAN SPEED D H W 6300 rpm 210 Hz 1650 rpm 55 Hz Qmw Input Net Max 29 0 kW min 6 8 kW D H W PRESSURE PMW Max 10 bar 147 p s i D H W PRESSURE PMW min 0 8 bar 118 p s i To obtain heat input 1 2 bar D H W MINIMUM FLOW RATE 3 l min FLUE OUTLET NOM DIAMETER 100 mm specially supplied with boilers If required DESTINATION BE FR amp GR CATEGORY ls DESTINATION GB IE CH ES IT PT amp GR CATEGORY 12 FLUE TYPE C13 C33 C53 NO 5 SEDBUK TABLE
66. 9 5 kW NOMINAL HEAT OUTPUT CONDENSING 21 4 kW MINIMUM HEAT OUTPUT 3 6 kW MINIMUM HEAT OUTPUT CONDENSING 4 0 kW GAS RATE max 931 0 8 m h AFTER 10 MINUTES min 0 15 m h INLET PRESSURE G31 37 FAN SPEED Max 4200 rpm 140 Hz Combustion 10 5 0 5 0 5 Case min 1300 rpm 43 Hz 10 5 0 5 0 5 Case OFF ELECTRICAL SUPPLY 230 V 50 HZ POWER CONSUMPTION 110 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 3 15A 20 mm to BS 4265 DRY WEIGHT 28 kg WATER CONTENT C H 0 8 litre WATER CONTENT 0 2 litre GAS SUPPLY CONNECTION 15 mm compression isolating valve FLOW CONNECTION C H 22 mm compression isolating valve RETURN CONNECTION C H 22 mm compression isolating valve INLET CONNECTION D H W 15 mm compression isolating valve OUTLET CONNECTION D H W 15 mm compression valve SAFETY DISCHARGE C H 15 mm copper pipe CONDENSATION DRAIN 3 4 21 5 mm push fit over flow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C H MAX PRESSURE PHS 2 5 bar MINIMUM WORKING PRESSURE 0 5 bar 7 LITRES EXPANSION VESSEL PRE CHARGE PRESSURE 0 5 bar CENTRAL HEATING OPERATING TEMPERATURE 80 35 C DESIGN FLOW RATE 1383 20 C RISE MINIMUM FLOW RATE C H 350 D H W FLOW RATE 30 rise 11 9 l min D H W FLOW RATE 35 rise 10 2 l min D H W FLOW RATE 40 rise 8 9 l min 10 inlet temperature D H W TEMPERATURE Max 60 C min 35 FAN S
67. AND LEFT WITH THE APPLIANCE COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Once the process of commissioning the boiler is complete the commissioning engineer MUST complete his section in the Benchmark log book CHECKING THE FLUE SYSTEM The flue system should be visually checked for The temperature of the water will depend on soundness Check all connections and fixings the rate at which it flows If due to high water are secure and tight pressure the flow rate is too high and the temperature too low for practical use the flow CHECKING THE HEATING THERMOSTAT rate may be adjusted It is better to set for the lowest acceptable temperature preferably at Allow the system to warm up and then turn the bath tap since the user can gain higher the C H thermostat to ensure the main burner temperatures at other restricted flow taps modulates from high to low and low to off If the cold supply is subject to large and vice versa scale range covers approx fluctuations or is above the permitted 45 C 80 C max water pressure a suitable pressure flow regulator should be fitted in the TESTING AND REGULATING THE cold water supply to the appliance DOMESTIC HOT WATER SYSTEM FLOW Slowly close the draw off tap to reduce the flow rate to the min approx 2 8 litre min CHECK THE OPERATIONAL WORKING Rotate the D H W control knob to
68. CTRICAL SUPPLY 230 V 50 HZ POWER CONSUMPTION 119 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 3 15A 20mm to BS 4265 DRY WEIGHT 29 kg WATER CONTENT C H 0 8 litre WATER CONTENT 0 2 litre GAS SUPPLY CONNECTION 15 mm compression isolating valve FLOW CONNECTION C H 22 mm compression isolating valve RETURN CONNECTION C H 22 mm compression isolating valve INLET CONNECTION D H W 15 mm compression isolating valve OUTLET CONNECTION D H W 15 mm compression valve SAFETY DISCHARGE C H 15 mm copper pipe CONDENSATION DRAIN 3 4 21 5 mm push fit over flow MAX COLD WATER CAPACITY WITHOUT ADDITIONAL EXPANSION VESSEL 110 LITRE SEALED WATER SYSTEM C H MAX PRESSURE PHS 2 5 bar MINIMUM WORKING PRESSURE 0 5 bar 7 LITRES EXPANSION VESSEL PRE CHARGE PRESSURE 0 5 bar CENTRAL HEATING OPERATING TEMPERATURE 80 C 35 C DESIGN FLOW RATE 1811 20 RISE MINIMUM FLOW RATE C H 350 D H W FLOW RATE 30 rise 14 0 l min D H W FLOW RATE 35 C rise 12 0 l min D H W FLOW RATE 40 rise 10 5 l min 10 C inlet temperature D H W TEMPERATURE Max 60 C min 35 FAN SPEED D H W 4800 rpm 160 Hz min 1300 rpm 43 Hz Qmw Input Net Max 30 1 kW min 4 1 kW D H W PRESSURE PMW Max 6 5 bar D H W PRESSURE PMW min 0 5 bar D H W MINIMUM FLOW RATE 2 5 l min FLUE OUTLET NOM DIAMETER 100 mm specially supplied with boilers If required DESTINATION GB IE ES IT PT amp GR CATEGORY llzuse FLUE TYPE Cis Cas
69. EMOVE REPLACE FLUE Float Outlet plastic TEMPERATURE SENSOR Fig 61 on ring a flexible pipe eee iil Remove front casing sect 8 1 4 Seal Detach the electrical plug and unscrew the sensor Cap Replace in reverse order TO REMOVE REPLACE THE WATER PRESSURE GAUGE Fig 51 dnd removi Flue temperature sensor Remove front casing sect 8 1 4 Remove the bottom panel and the right side panel Drop down control box sec 8 20 Close the on off valves for the heating circuit and drain the water at the drain point Fig 35 Remove the retaining clip on gauge pipe Fig 51 Remove the pressure gauge from the instrument panel by pressing its fastening springs EXTERNAL CONTROL CONNECTION Replace in reverse order Fig 62 Remove front and bottom of the casing sect 8 1 4 Remove the external wire link on the Fan frequency PCB box control 2 E d Replace with external wire controls External control C connection TM FAN FREQUENCY CONTROL Fig 62 Remove front casing sect 8 1 4 Connect the instrument to the PCB box fig 62 Instrument panel box bottom view 9 FAULT FINDING CENTRAL HEATING Before trying to operate the boiler make sure that All gas supply cocks are open and the gas supply has been purged of air The heating system pressure is at least 1 bar min
70. ERHEAT THERMOSTAT Fig 1 item 25 Remove front casing sect 8 1 4 Remove the two wires that connect to the overheat thermostat DHW diverter valve mechanism Unscrew the thermostat to the heat exchanger and remove Replace in reverse order TO REMOVE REPLACE LOW WATER OR DIFFERENTIAL PRESSURE SWITCH Fig 53 Remove front casing sect 8 1 4 Remove the bottom panel and the right side panel Close the on off valves for central Heating circuit and drain the water from the boiler Fig 35 Pull wires off and unscrew the low water pressure switch from pump manifold Remove the retaining clip that fix the electrical connection and unscrew the nut at the flow water pressure switch Replace in reverse order fill the system as described in sect 6 4 and check for leaks TO REMOVE REPLACE SAFETY DISCHARGE VALVE Remove front casing sect 8 1 Drop down control box sec 8 20 Close the on off valves for central Heating circuit and drain the water from the boiler Fig 35 Unscrew the screw below the valve Remove the securing clip and remove the pipe Detach the valve Replace in reverse order fill the system as described in sect 6 4 and check for leaks TO REMOVE INSTRUMENT PANEL Remove front casing see sect 8 1 4 Differential pressure switch Retaining Clip A Electrical connection Fig 53 Low water pressure switch Push the four retaining latches
71. Fig 2 Illustrates the operating principles described in section 2 DESCRIPTION OF CONTROL SYSTEM AND SEQUENCE OF OPERATION Domestic hot water mode When the appliance is in rest mode with the mains neon switch on Switch the summer winter switch to summer position with the heating circuit charged with water above 1 bar If the domestic hot water tap is turned on the boiler will function in the following sequence The pump starts The fan starts and sends a signal back to the ignition board that the fan is running The spark ignition system is powered which in turn commences the spark igniter to operate and light the burner At this point the ignition board opens the gas valve to light the burner When the electrode sensor senses the signal that the burner is alight the spark igniter stops From the fan speed setting the boiler increases to the maximum permissible speed over a period of 5 seconds and will remain at its maximum required power until its maximum regulated temperature is achieved and then will modulate to maintain this When the domestic hot water tap is closed the diverter valve goes back into rest mode the burner is shut down along with the fan which is also switched off Central heating mode If the switch is positioned on winter with a demand for heat to supply radiators etc with the heating circuit fully charged above 1 bar so as to operate the low water sensor device the boiler will start
72. GA should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer s instructions KEY CO carbon monoxide carbon dioxide O2 oxygen Combustion Ratio The CO reading measured in ppm divided by the CO 2 reading first converted to ppm ppm parts per million Setting to Minimum Rate 1 Put boiler in Test mode function see section 6 16 2 Create a CH demand by ensuring that the system controls are requesting heat and the boiler is set in the Winter Position 3 Press the arrow down button to set the minimum fan speed 5 The function is enabled for maximum 15 minutes press reset to esc test mode 12 1 ANALYSER CHECK LIST Set Boiler to Maximum Gas Rate In accordance with boiler instructions set boiler to operate at maximum rate full load condition Allow sufficient time for combustion to stabilise Note Do not insert analyser probe during this period to avoid possible Carry Out Flue Integrity Check Using Analyser Insert analyser probe into air test point where available and allow readings to stabilise Note Where no air inlet test point is provided then a flue integrity check with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the Prior to CO level
73. Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Co Com Signature Signature All installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer Heating and Hotwater Industry Council HHIC THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk THE WHITE BOILER COMPANY Instructions for Use Installation and Servicing To be left with the user HIGH EFFICIENCY CONDENSING COMBINATION BOILER WH 100 T WH 130 Natural Gas G20 Lae LPG G30 G31 I G C No Listed by The United Kingdom Water Fitting Byelaws Scheme COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Technical and illustrative data are not binding and can be modified without prior notice The descriptions and illustrations in the present booklet are for guideline purposes only THE WHITE BOILER COMPANY a Ravenheat Group Compan CHARTISTS WAY MORLEY LEEDS LS27 9ET TEL 0044 0 113 252 7007 FAX 0044
74. ID110050 125 80 to 100 60 Flue reducer Available on vequieat from CUR110250 297 flue bend 80 125 THE WHITE BOILER COMPANY CUR110300 90 elbow flue bend 80 125 Chartist Way Morley Leeds West Yorkshire TERO010050 Horizontal Flue Terminal 80 125 ENGLAND 1527 U K TER110200 Vertical Flue Terminal 80 125 Tel 0044 0 113 252 7007 TEGO60050 Flashing sleeve slate ASSEMBLE BOILER Manual air vent Fitting valve pack Remove plastic caps from boiler connection and fit valves as per Fig 31 using washers provided It is recommended fixing the valve pack before installing the boiler on the wall GAS CONNECTION Fig 31 A minimum working gas pressure of 20 mbar 8 in w g must be available at the boiler inlet at full flow rate 37 mbar for propane 29 mbar for butane Fit gas service cock to the boiler via the union nut and connect gas pipe Do not overtighten and use another spanner as a counter force to avoid straining internal connections Important consult sect 4 5 1 CENTRAL HEATING CONNECTION Fig 31 Before any central heating connections are made to the boiler all system valves should IMPORTANT be opened and the system thoroughly flushed when initially filling the system with the front out with cold water cover off open the manual air vent fig 30 conned the central eae tacking care to avoid spilling water and the isolating cock re close prior to commissioning and Connect th
75. It is recommended fitting the valve pack before installing the boiler on the wall GAS CONNECTION Fig 29 A minimum working gas pressure of 20 mbar 8 in w g must be available at the boiler inlet at full flow rate 37 mbar for propane 29 mbar for butane Fit the gas service cock to the boiler via the union nut and connect gas pipe Do not over tighten and use another spanner as a counter force to avoid straining internal connections Important consult sect 4 6 CENTRAL HEATING CONNECTION Fig 29 Before any central heating connections are made to the boiler all system valves should be opened and the system thoroughly flushed out with cold water Connect the central heating return pipe to the isolating cock Connect the central heating flow pipe to the isolating cock marked CHF Pipe dimensions and positions are marked on template supplied fig 30 Drain point Central heating flow CH 22 mm Fig 29 Domestic inlet water 15mm POSITION OF WATER GAS CONNECTIONS DOMESTIC CONNECTIONS COMBI BOILER Fig 30 Drill wall if required Gas inlet CH flow 15 22 DHW outlet ee ari Domestic Hot Water outlet DHW Relief valve DHW inlet 15 mm DOMESTIC WATER CONNECTION Fig 29 The domestic hot water circuit does not need a safety valve but it is essential to ensure that the pressure of the cold water supply does not exceed 10 bar If in doubt it is advisable to i
76. Jaye 3ndu OLN eniJ SPARE PARTS 11 THE WHITE BOILER COMPANY WH 80 90 HIGH EFFICIENCY CONDENSING COMBINATION BOILER SHORT LIST OF SPARE PARTS AND FLUE ACCESSORIES G C Description Part No CIR150100 Digital display PAN150050 Instrument panel CIR150050 Control board SCA110051 Instrument panel box FUS010150 Internal fuse 3 15 A TRA15010 Water pressure transducer FOR150250 gt Water pressure transducer clip GRU150100 Return manifold GRU150100 Turbine manifold formoso _____ _______ eat exchanger Oring m fscmsorso plate heat exchanger scatso20 _____ ______ a vans OO ____ Fowmad 4 15 5018005 _____1 ________1 2 gasket GUA010200 i5 Seeyreefvaveppe az mms s Fewdeedorswih 000 BHWsemo O 20
77. LOW RATE 1811 I h 20 C RISE MINIMUM FLOW RATE 503 l min D H W FLOW RATE 30 rise D H W FLOW RATE 35 rise 17 0 l min 14 5 l min D H W FLOW RATE 40 rise 12 7 l min 10 inlet temperature D H W TEMPERATURE FAN SPEED D H W Max 60 C Max 6300 rpm 210 Hz min 40 min 1650 rpm 55 Hz Qmw Input Net Max 36 4 kW min 7 8kW D H W PRESSURE PMW D H W PRESSURE PMW D H W MINIMUM FLOW RATE 10 bar 147 p s i min 0 8 bar 118 p s i l min To obtain heat input 1 2 bar FLUE OUTLET NOM DIAMETER 100 mm specially supplied with boilers If required DESTINATION AT DK Fl SE GR DESTINATION GB IE CH ES IT PT amp GR FLUE TYPE C13 C33 Css CATEGORY 2 CATEGORY 112 NO 5 SEDBUK SECTION3 TECHNICAL TABLE 1 D WH 130 T LPG G 30 G 31 Is IIzus NOMINAL HEAT INPUT NET QMS 29 6 kW MINIMUM HEAT INPUT NET 7 8 kW NOMINAL HEAT OUTPUT 29 0 kW NOMINAL HEAT OUTPUT CONDENSING 32 0 kW MINIMUM HEAT OUTPUT 7 6 kW MINIMUM HEAT OUTPUT CONDENSING 8 4 kW GAS RATE max G31 1 3 m h G30 0 99 m h AFTER 10 MINUTES min 0 3 m h 0 25 INLET PRESSURE G31 37 mbar G30 28 30 mbar FAN SPEED C H Max 4800 rpm 160 Hz Combustion CO G31 10 2 0 2 0 5 Case ON min 1650 rpm 55 Hz G30 11 0 0 2 0 5 Case ON FAN SPEED Max 4800 rpm 160 Hz Combustion CO G31 9 9 0 2 0 5 Case OFF min 1650rpm 55Hz G30 10 8 0
78. Monday to Sunday TABLE 2 Group 5 Day 1 2 5 4 5 6 Monday to Saturday Group SA SU Day 6 7 Saturday to Sunday Group MO FR Day 1 2 5 4 5 Monday to Friday 1 9 DIAGNOSTIC The display shows eventual error or faulty message Stop boiler The boiler stops the operating cycle and waits for the disappearance of the cause of the error in order to go back to be operating mode Block boiler The boiler requires a manual reset to become operational again 2 0 GENERAL LAYOUT Fig 3 KEY 1 Condensate trap 2 Gas valve 3 Gas inlet 4 Drain point 5 CH flow 6 Diverter valve motor 7 DHW outlet 8 DHW sensor 9 DHW flow detector 10 DHW inlet 11 Safety pressure relief valve 12 Water pressure transducer 13 CH retum 14 Control board 15 Circulation pump 16 Automatic air vent 17 Condensate drain 18 Expansion vessel 19 Main heat exchanger 20 Spark electrod
79. PEED D H W 4800 rpm 160 Hz min 1300 rpm 43 Hz Qmw Input Net Max 25 4 kW min 3 7 kW D H W PRESSURE PMW Max 6 5 bar 147 p s i D H W PRESSURE PMW min 0 5 bar 118 p s i D H W MINIMUM FLOW RATE 2 5 l min FLUE OUTLET NOM DIAMETER 100 mm specially supplied with boilers If required DESTINATION GB IE ES IT PT amp CATEGORY llzuse FLUE TYPE C13 C33 Css NO 5 SEDBUK IP X4 D TABLE 3 B 3 2 TECHNICAL DATA TABLE 3 C WH 90 T NATURAL GAS 20 IIzuse NOMINAL HEAT INPUT NET QMS 24 5 kW MINIMUM HEAT INPUT NET 4 1 kW NOMINAL HEAT OUTPUT 23 8 kW NOMINAL HEAT OUTPUT CONDENSING 26 2 kW MINIMUM HEAT OUTPUT 4 0 kW MINIMUM HEAT OUTPUT CONDENSING 4 4 kW GAS RATE max 2 6 m h AFTER 10 MINUTES min 0 4 m3 h INLET PRESSURE 20 mbar FAN SPEED Max 4200 rpm 140 Hz Combustion CO 9 0 0 5 0 5 Case ON C H min 1300 rpm 43 Hz 9 0 0 5 0 5 Case OFF ELECTRICAL SUPPLY 230 V 50 HZ POWER CONSUMPTION 119 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 3 15A 20mm to BS 4265 DRY WEIGHT 29 kg WATER CONTENT C H 0 8 litre WATER CONTENT 0 2 litre GAS SUPPLY CONNECTION 15 mm compression isolating valve FLOW CONNECTION C H 22 mm compression isolating valve RETURN CONNECTION C H 22 mm compression isolating valve INLET CONNECTION D H W 15 mm compression isolating valve OUTLET CONNECTION D H W 15 mm compression valve SAFETY DISCHARGE C H 15 mm copper pipe CONDENSATION DRAIN 3 4 21 5 mm
80. Position the flue sample point starter must length is not exceeded Fig 21 and table 3 be fitted and fix the securing screw on Mark the two wall fixing bracket securing the flue adaptor appliance Fig 23 item holes on the wall 66 and ensure that the gasket is correctly Detach the template from the wall fitted Use a 10 mm dia drill to make the 2 holes securing fixing hanging bracket Important Make sure that the flue Insert plastic expansion plugs Fig 18 extension dia 60 mm duct is inserted fully Screw in the two coach bolts into the flue manifold and the flue manifold rubber seal is correctly fitted Cut 105 mm diameter hole through the ceiling and or roof at the point previously marked Fit a roof flashing slate to the roof available from The White Boiler Company Insert the Vertical Flue terminal assembly through the flashing slate from the outside Fix the appliance to the wall locating onto the wall fixing bracket Measure the vertical distance between the top of the flue and the bottom of the flue terminal assembly Fig 22 The measurements should be taken from the outer diameter of the flue NOTE Where this length does not match any standard combination of the extensions only extension can be cut to the required length Fig 24 When cutting both inner and outer ducts of the extension always cut on spigot side and they must be de burred ACCESSORIES CONCENTRIC FLUE 60 100 EXTRAS Part No
81. REMOVE REPLACE EXPANSION VESSEL Fig 44 Unscrew and remove the bracket Remove front and bottom panels fig 39 40 Drain the CH circuit unscrew the fixing bracket and the nut connecting the expansion vessel Lift up the vessel and remove Replace in reverse order Use a new gasket taking care to ensure they are replaced correctly TO REMOVE REPLACE GAS VALVE Fig 45 Unscrew and lift up Remove front and bottom panels the expansion vessel fig 39 40 Unscrew the nut and the four screws on the bottom of the gas valve Replace in reverse order IMPORTANT when the gas valve is re fitted check combustion CO and adjust if necessary see section 6 9 TO REMOVE REPLACE PLATE HEAT EXCHANGER Fig 46 Remove front and bottom panels fig 39 40 gas valve pipe Remove the panel control box sect 8 23 Close off the on off valves for CH circuit and DHW circuit and drain the boiler and drain hot water from the lowest hot water tap Gasket ___ __ Gas valve Unscrew the two allen screws that m connect the DHW heat exchanger and E i HOT pull it out from the boiler fig 46 If necessary the pipes from the flow manifold may have to be removed for
82. THE WHITE BOILER COMPANY Instructions for Use Installation and Servicing To be left with the user HIGH EFFICIENCY CONDENSING COMBINATION BOILER WH 80 T Natural Gas G20 la Hus G C No 47 506 05 LPG 30 31 1 I G C No 47 506 06 2H 2 3 WH 90 T Natural Gas G20 Lu Hus G C No 47 506 07 LPG G30 31 1 II G C No 47 506 08 2H 2 3 Listed by The United Kingdom Water Fitting Byelaws Scheme THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Technical and illustrative data are not binding and can be modified without prior notice The descriptions and illustrations in the present booklet are for guidance purposes only THE WHITE BOILER COMPANY A Ravenheat Group Company CHARTISTS WAY MORLEY LEEDS LS27 9ET TEL 0113 252 7007 0113 238 0229 Website www ravenheat co uk E mail sales avenheat co uk HIGH EFFICIENCY CONDENSING BOILER FOR CENTRAL HEATING AND DOMESTIC HOT WATER This new highly efficient turbo modulating boiler is designed to meet domestic hot water and central heating requirements at super high efficiency POSITION The appliance is extremely versatile as it can be fitted in almost any room The appliance is room sealed so there is no contact between the combustion chamber and living accommodation This guarantees maximum safety and efficiency Each boiler has been designed and manufactured in our modern plan
83. TIOMETER R10 THIS IS SET AN SEALED THIS CAN BE CHECKED USING A FREQUENCY METER JP2 Fig 39a TABLE 5 A Range rating regulation of Central Heating C H regulations input kW Fan speed rpm Maximum setting minimum setting WH100 WH130 WH100 WH130 5400 iem 165 WH100 J RATIO BETWEEN FAN SPEED AND HEAT INPUT rpmx1000 66 60 MaxDHW MaxCH WH 100 T Low Nox Fan Speed rpm Btu h x 1000 3 409 54 8 136 5 145 0 kW 4 8 12 16 20 24 28 32 36 40 44 Heat Input G20 G30 631 6 68 2 81 9 95 5 109 2 122 TABLE 5 B Range rating regulation of Domestic Hot Water D H W regulations Heat input KW Fan speed rpm WH100 WH130 WH100 WH130 minimum setting 1650 1650 14 With jumper keep hot Control board 8 JP14 5 8 16 With jumper test function mode digital display Co 1 6 Winter position max fan speed Summer position min fan speed Board potentiometer R9 CH max fan speed R10
84. This operation may in some cases be heard for a short period when the pump has been activated The heat exchanger in the D H W circuit is a stainless steel plate heat exchanger water to water and domestic water is heated by converting the water in the central heating circuit The transfer of heat is very high because the two fluids move in a counter direction Select the winter position by summer winter button item 1 fig 1 When hot water is turned on the diverter valve motor moves to exclude the central heating circuit the boiler automatically modulates to maintain the domestic hot water at a constant temperature The water temperature can be regulated by the digital display When domestic hot water is being drawn off the burner and pump perform as they do during central heating except that the burner is commanded by the D H W thermostat When D H W is no longer called for tap is turned off the boiler will automatically return to the central heating mode Select the summer position by pressing the summer winter button The boiler functions like an automatic gas hot water heater When D H W is no longer required the burner and pump and fan will immediately turn off 2 7 OVERALL DIMENSION Fig 5 Ds 7 mm Max This also takes place when in winter mode if there is no demand for heat to the central heating system or until the digital clock and r
85. Unscrew the C H diverter valve as in Fig 52 leak Replace in reverse order NOTE Fit a new O ring NOTE Always use new O ring TO REMOVE REPLACE THE CENTRAL HEATING AND OR DOMESTIC HOT TO REMOVE REPLACE DHW WATER THERMISTOR Fig items 27 8 DIVERTER VALVE MECHANISM Fig 52 Remove front casing sect 8 1 4 Remove the bottom panel and the right side 8 15 2 Remove the wires that connect the panel thermistors 8 15 1 Remove front casing sect 8 1 4 Drop down control box sec 8 20 8 15 3 For C H thermistor remove the retaining clip from the pipe Close the on off valve for the DHW circuit and drain the hot water from the lowest hot 8 15 4 For D H W thermistor close the on off valve water tap for the DHW circuit and drain the hot water from the lowest hot water tap Remove the flow detector as fig 52 Unscrew the thermistor Unscrew the DHW diverter valve as in NOTE When reconneting the polarity fig 52 of the wiring to thermistor is unimportant Replace in reverse order Replace in reverse order and replace the D H W thermistor gasket NOTE Always use new O ring Auto air vent valve C H return Pressure gauge securing clip Type UPSO 15 50 CESAO2 P N 97795110 230V 50Hz PC 1048RAV p Pump securing clip Front view Fig 51 Over view Wire connector REMOVE REPLACE OV
86. Water pressure transducer easier access Lift up the plate heat exchanger Replace in reverse order NOTE Always use new O rings REMOVE REPLACE THE WATER PRESSURE TRANSDUCER Fig 45 Plate heat exchanger Remove front and bottom panels fig 39 40 Close the on off valves for the heating circuit and drain the water at drain point fig 36 Detach the wire connector remove the securing clip Replace in reverse order Unscrew the two allen screws and lift up the plate heat exchanger REMOVE REPLACE DIVERTER VALVE 8 15 MOTOR Fig 47 Remove front and bottom panels fig 39 40 Detach the electrical plug and remove the retaining clip Replace in reverse order TO REMOVE REPLACE C H DIVERTER VALVE Fig 47 Remove front and bottom panels fig 39 40 Remove the panel control box sect 8 23 Close the on off valves for the heating circuit and drain the water at drain point 19 36 Remove diverter valve motor switch to allow access and unscrew the Diverter valve motor C H diverter valve fig 47 Replace in reverse order NOTE Always use new O ring Diverter valve motor retaining clip Se CH diverter valve switch 8
87. ance 127 mm between the centre of flue duct hole to the corner Detach the template from wall Use a 10 mm dia drill to make the 2 holes for the fixing bolts Insert the plastic expansion plugs Core drill a 105 mm dia hole in the side wall for inserting the flue duct Fit the elbow header into the flue flange on the top of the boiler positioning it towards the required direction Important Make sure that the dia 60 mm on the elbow header is inserted fully into the flue manifold and the flue manifold rubber seal is correctly fitted Fig 17 item 65 If using the horizontal flue duct and it is too long it can be shortened Should it be necessary to cut the flue always cut on right angles and ensure the cut is de burred Note Add 30 mm to overall flue length to allow for terminal rubber wall seal fig 10 item 127 REAR FLUE OUTLET Drilling template min 125 mm dis mm ang d Fixing bolts and wall plugs Lower securing position if required min 215 mm min 195 mm Insert the flue assembly into the wall making sure it will not interfere when fixing the boiler on the wall Lift the boiler on the wall locating onto the two fixing bolts Tighten the two bolts using a spanner to secure to the wall Working above the boiler pull the flue duct towards the elbow in order to engage the tube into its header fig 10 Position the flue elbow in li
88. and remove the front of the instrument panel Fig 55 Rotate the instrument panel and put it in the service retaining clip instrument panel box bracket Fig 56 TO REMOVE CONTROL PANEL BOX Fig 57 Remove front casing see sect 8 1 4 To move the control panel box into service position Draw forward the control panel box with both hands until it is slighty out of the boiler As doing so move the box over to the left while still pulling it forward until the control box becomes free This will allow free access to lower part of the boiler REMOVE REPLACE CONTROL BOARD Fig 59 Remove front casing sect 8 1 4 Remove instrument panel sect 8 19 2 to 8 19 3 Detach the connectors from the board Detach the PCB board from its base by unscrewing the four securing screws Fig 59 Replace in reverse order NOTE When refitting the control panel ensure the leads are not trapped TO REMOVE REPLACE TIMECLOCK Remove front casing sect 8 1 4 Remove instrument panel sect 8 19 2 to 8 19 3 Pull the two securing clip that fasten the timeclock to the panel instrument and pull it out Carefully remove the four wire connecting timer Replace in reverse order NOTE Ensure all electrical connections are made correctly Control panel box bracket Retai TO REMOVE REPLACE DIGITAL DISPLAY BOARD Remove front casing sect 8 1 4 Remove instrument panel sect 8
89. appliances in the property working Put the appliance in summer position item1 fig 1 Open domestic hot water tap preferably the bath tap Ensure the cold water inlet stopcock is open and the D H W is set at maximum press the arrow up item 3 fig 1 the digital display shows the set temperature if necessary adjust with arrow up and arrow down buttons After a few seconds the digital display shows water temperature in demand D H W icon flashing item 12 fig 2 If the boiler does not light check that the water flow rate is above the min required to operate the differential pressure 2 8 Lts min 0 61 gals min The temperature of the water will depend on the rate at which it flows If due to high water pressure the flow rate is too high and the temperature too low for practical use the flow rate may be adjusted It is better to set for the lowest acceptable temperature preferably at the bath tap since the user can gain higher temperatures at other restricted flow taps If the cold supply is subject to large fluctuations or is above the permitted max water pressure a suitable pressure flow regulator should be fitted on the cold water supply to the appliance Slowly close the draw off tap to reduce the flow rate to the min approx 2 8 litre min Select a different temperature for D H W to ensure it operates at its various setting Close the draw off tap still further The burner should stop when the rate
90. ast five minutes or until the unit has reached its operating temperature Unscrew the test sample screw on the boiler elbow bend item 60 fig 10 Measure the level of CO Check the reading against the corresponding value in table 10 and with reference to page 63 Fig 37 It is essential that this test is repeated with the casing on as this will check the integrity of the flue If adjustment proves necessary then proceed as follows IMPORTANT Any adjustment to the gas valve should only be carried out by a qualified person Referring to the table 10 adjust the maximum level of CO with the Throttle using a 4 mm hex on the gas valve fig 35 Anti clockwise to decrease CO Clockwise to increase CO After any new regulation wait to stabilise for about one minute Replace the front cover TABLE 10 coz NAT GAS 9 0 0 5 0 5 10 5 40 5 0 5 IMPORTANT Do not insert the analyser probe into the sample point immediately or leave in long periods This will prevent saturation of the analyser During the calibration function the combustion ratio may increase for a short time while the boiler performance is optimised The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturer s require
91. at Work Regulations 1989 The manufacturer s notes must NOT be taken in any way as overriding statutory obligations IMPORTANT These appliances are CE certificated for safety and performance It is therefore important that no external control devices e g flue dampers economisers etc are directly connected to this appliance unless covered by these Installation and Service Instructions or as otherwise recommended by Ravenheat in writing If in doubt please enquire Any direct connection of a control device not approved by The White Boiler Company could invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety regulations and the above regulations NOTE The White Boiler Company WH 100 130 combi boiler has been tested and examined by BSI and is certified to comply with PrEN 483 and BS EN 625 Manufacturers instructions must NOT be taken in any way as overriding statutory obligations If in doubt on any point please consult The White Boiler Company LOCATION OF BOILER Siting of The White Boiler Company WH100 130 combi boiler must be as follows The position of installation should be within the building unless otherwise protected by a suitable enclosure Adequate space for installation servicing and air circulation around boiler must be allowed for The The White Boiler Company WH 100 130 combi boiler must be fitted on a flat and vertical wall capable of adequately
92. ater supply even through a non return valve without the approval of the Local Water Authority should not present any problem 4 8 10 Permissible methods of filling Filling loop Control valve Control valve Supply pipe Return pipe Double Temporary connection check valve Supply pipe Figure depicts the requirements of Diagram R24 2a of the Water Supply Water Fittings regulations 1999 SIZING OF ADDITIONAL EXPANSION VESSEL TABLE 2 Deduct from the value given in the table the 7 litre vessel supplied Safety 3 0 valve setting bar Vessel charge pressure bar Initial system pressure bar Total water content of system Litres For system volumes other than those given above multiply the system volume by the factor across Note This pressure can be increased up to 1 5 bar to suit high static head situations B Where fitting of a make up vessel would be difficult re pressurisation of the system can be done See section on FILLING If the capacity of the central heating system should exceed 110 Litres an additional vessel should be installed on the return to the combination boiler from the heating system Fig 7 Guidance on vessel sizing is given in Table 2 If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleaning BS 7593 2006 details the steps necessary to clean domestic central heati
93. be to the combustion analyser test point IMPORTANT After completing any servicing or replacement of gas carrying components it is essential that a test for gas soundness is always carried out along with functional checks in operation TO INSPECT AND CLEAN THE APPLIANCE Before carrying out the cleaning operation cover the electrical control panel with a piece of waterproof material to protect it from debris Inspect the heat exchanger for any blockage Deposits of any material should be brushed away using a soft brush NOTE Do not use brushes with metallic bristles Examine internal pipe work connections and automatic air vent for any water leaks and rectify if necessary Examine and remove loose debris from the combustion chamber using a soft brush and vacuum cleaner Carefully flush by spraying water at any remaining debris through the condensate trap Ensure the water is kept away from electrical components Inspect the siphonic condensate trap for a blockage Remove the cap at the base of the condensate trap Remove any debris found Remove the float to clean it Any deposits should be flushed out Reassemble and refit the condensing trap When refitting the cap ensure that a watertight seal is achieved but do not use excessive force Examine the spark and sensing electrodes for any mechanical damage Clean away any debris and check the spark and sensing gap Examine flue duct and flue manifold a
94. cal connections Outdoor sensor Commissioning Gas supply installation Electrical installation Initial filling of the system Setting the heating system design pressure Filling the hot water system Lighting the boiler Check the gas pressure Combustion check Sections Sections 6 11 6 12 6 13 6 14 6 15 6 16 Checking the heating thermostat Spare parts Testing regulating the D H W flow Keep hot Benchmark commissioning C H high low temperature checklist details Range rating central heating or and 1 Analyser check list domestic hot water Test mode Instructing the user Servicing instructions Boiler frost protection To inspect and clean the appliance Replacements of parts General To remove front panel To remove left and right panels To remove replace spark igniter box To remove replace fan To remove replace the electrodes To remove replace the burner To remove replace the heat exchanger To remove replace expansion vessel To remove replace gas valve To remove replace plate heat exchanger To remove replace the water pressure transducer To remove replace diverter valve motor To remove replace C H diverter valve To remove replace D H W diverter valve mechanism To remove replace pump To remove replace automatic air vent To remove replace safety relief valve To remove replace D H W sensor To remove replace C H flow and return sensors To remove replace flue sensor To clean and remove rep
95. ccordance with the manufacturer s instructions The operation of the boiler and system controls have been demonstrated to and understood by the customer The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature installations in England and Wales must be notified to Local Authority Building Control either directly or through a 7 enc GN Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer AND SERVICING OF DOMESTIC HEATING AND WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls SERVICE 01 SERVICE 02 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min ra
96. ced TO REMOVE REPLACE FAN Fig 42 43 Remove front panel only sect 8 1 4 Remove three manifold burner retaining nuts Fig 42 Pull forward and lift up manifold slighty to remove Detach power supply cables to fan Fig 42 The fan and the manifold can then be remove from the boiler To separate the fan from manifold remove the two retaining bolts and the three screws retaining the air gas mixture plate Fig 43 44 Reassemble in reverse order Ensure wires are connected correctly Air gas manifold Fan gasket Air gas mixtur Secu Bolts securing fan Fan TO REMOVE REPLACE THE BURNER FIG 45 Remove front casing sect 8 1 4 Follow instruction to remove fan sect 8 4 to 8 4 3 Remove the burner from the main heat exchanger Important the burner gasket may require replacing Replace in reverse order TO REMOVE REPLACE THE HEAT EXCHANGER Remove front casing sect 8 1 4 and the bottom left and right side panels Drain the boiler CH circuit and drain the DHW circuit Follow instruction to remove fan sect 8 4 to 8 4 3 Remove the clip securing the condense pipe out of the bottom of the heat exchanger and pull down to remove the pipe Disconnect the flow and return pipes at the heat exchanger Dis
97. cing or replacement of components always isolate electricity supply to the appliance and always turn off the appliance gas supply at the gas service cock The Data badge is positioned low on left panel The following notes apply to the appliance andits controls but it should be remembered that attention must also be paid to the heating and hot water circuits with special attention to radiator valves thermostats clocks leaking hot water taps etc Where it is necessary to replace a gasket that relies on adhesive for securing this adhesive will be supplied with the gasket as a spare item In all cases prior to servicing remove the front panel of the case Operate the appliance by turning the hot water services on to a high water flow measurement of the products of combustion can be achieved by connection of a probe to the combustion analyser test point IMPORTANT After completing servicing or replacement of gas carrying components it is essential that a test for gas soundness is always carried out along with functional checks in operation TO INSPECT AND CLEAN THE APPLIANCE Before carrying out cleaning operation cover the electrical control panel with a piece of waterproof material to protect it from debris Inspect the heat exchanger for any blockage Deposits of any material should be brushed away using a soft brush NOTE Do not use brushes with metallic bristles Examine internal pipe work connections
98. connect the pipes at the flow manifold and pump then move away from the heat exchanger Disconnect the pipes to the expansion vessel Remove the spark igniter box sect 8 2 Loosen the four heat exchanger securing screws and clamps then carefully ease heat exchanger out CAUTION There will be water in the heat exchanger Replace in reverse order always use a new O rings seals Manifold burner Gasket burner Burner Retaining nuts T Unscrew the retaining nuts pull forward and lift up manifold slighty to remove TO REMOVE REPLACE GAS VALVE Fig 46 Remove front casing sect 8 1 4 Remove the bottom panel and the left side panel Drop down the control panel into the service position Fig 55 Unscrew and disconnect gas valve pipe Fig 46 Remove the electrical plug from the gas valve and unscrew the four screws to the gas inlet pipe Remove the gas valve Reassemble in reverse order and replace the gasket IMPORTANT When gas control valve Will be re fitting check combustion CO and adjusted if necessary see section 6 9 Unscrew and disconnect gas valve pipe Gasket
99. cticable discharge can be allowed into the external household drains or a purpose designed soak away It is recommended that any external condensate drain pipe is insulated and also must be of 40 mm 1 1 2 diameter through the outside wall to prevent freezing in adverse weather conditions It is not necessary to provide air breaks or extra traps in discharge pipe as there is already a 125mm high trap inside the boiler Fitting an extra trap may cause the boiler siphon to work incorrectly Refer to 55546 or BS67968 for advice on disposal of boiler condensate Notes ALL EXTERNAL PIPE RUNS MUST BE IN ACCORDANCE WITH BS 6798 1 INTERNAL TO SINK WASTE UPSTREAM OF SINK WASTE TRAP Open end of pipe direct into gulley below grating but above water level Ground level 2 INTERNAL CONNECTION TO SOIL VENT STACK Make connection to SVP using a solvent welded saddle TERMINATION TO SOAK AWAY 4 TERMINATION TO DRAIN GULLY External wall External wall nr Lt Termination Lt Open end of pipe direct to soak away into gulley below grating bul above water level From this point must 40 CONVERTING THE APPLIANCE It is essential that all external controls TO DIFFERENT GAS TYPES are VOLT FREE Boilers are factory set to work for use Factory fitted internal wiring must not be with Natural gas or LPG gas This i
100. ction Printed circuit board designed to connect to room stat and or timer frost stat Aesthetically pleasing panels and controls On Off ball valves for shutting off gas central heating and domestic hot water circuit Safety relief valve for safety discharge Programmable 7 day module with digital display optional model All front panel controls not often used have been hidden This achieves simplicity of operation with easy to clean panels NOTE Due to the high efficiency of this boiler a plume of water vapour will form at the flue terminal during operation COSHH CONTROL OF SUBSTANCES HARMFUL TO HEALTH IMPORTANT This appliance contains materials that are indicated below It is the Users Installers responsibility to ensure that the necessary personal protective clothing is worn when handling where applicable the pertinent parts that contain any materials that could be interpreted as being injurious to health and safety WARNING when installing the appliance care should be taken to avoid any possibility of injury when handling sheet metal parts GENERAL INFORMATION GLUES AND SEALANTS exercise caution if these are still in liquid form INSULATION PADS CERAMIC FIBRE may be harmful if inhaled may be irritating to skin eyes nose and throat When handling keep dust generation to a minimum avoid inhaling and contact with skin or eyes When disposing of the product keep dust generation to a minimum and ensure that parts ar
101. d m Equivalent length of 90 bend m OPTIONAL EXTRAS PLUME MANAGEMENT KIT Fig 12 Max 6000 mm flue extension duct as an extra cost only when requested to reduce pluming nuisance of condensation from 60 100 horizontal concentric flue Plume Management Kit Maximum Length minimum length mm mm Equivalent length of 45 bend mm Equivalent length of 90 bend mm The Maximum permitted flue length is measured from the centre line of the flue terminal to the top of the outlet terminal IMPORTANT Max flue length must not exceed 6 m with a horizontal concentric 60 100 flue of 3m L Plume Management Kit Part No Part No Description TER110101 Fig 12 1 terminal bend 1 90 elbow bend 2 45 bend 1 metre 60 M F flue length 1 flue length bracket 1 n n n n n metre high plume kit containing CUR110050 45 flue exhaust deflection bend Fig 12a CUR110100 90 flue exhaust deflection bend Fig 12a IMPORTANT Please lubricate the internal part of the seals before being fitted FLUE EXHAUST DEFLECTION BEND Fig 12a Flue exhaust deflection bend are also available These come in both 45 and 90 degree versions These bends fit directly onto the flue exhaust terminal to deflect the flue gas plume in an upward or sideways direction Although they are not substitute for a plume kit they can be considered useful where condensate plu
102. display Explain and demonstrate the function of the temperature controls radiator valves etc for the economic use of the system If an external time clock is fitted then draw attention to the digital time Stress the importance of regular servicing by a qualified Heating Engineer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR Fill in the Benchmark log book and leave completed with the customer Explain to the user how to isolate the appliance from the gas water and electricity supplies and the locations of all drain points SERVICING INSTRUCTIONS The White Boiler Company is a member of the Benchmark initiative and fully supports the aims of the programme Benchmark was instructed to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency Denchmari 7 1 BOILER FROST PROTECTION The appliance has a built in frost protection device that protects the boiler from freezing With the gas and electric supplies ON and irrespective of any room thermostat setting the frost protection device will operate the pump when the temperature falls below 10 and will operate the burner when the temperature falls below 5 C The burner will switch off when the temperature reaches 27 C When the frost protection device operates AF is displayed on the digita
103. dulating boiler is designed to meet domestic hot water and central heating requirements at super high efficiency unheard of only a few years ago POSITION The appliance is extremely versatile as it can be fitted in almost any room The appliance is room sealed there is no contact between combustion chamber and living accommodation This guarantees maximum safety and efficiency Indeed our front cover has been designed to fit achieving maximum air tight seal using screw down fasteners Each boiler has been designed and manufactured in our modern plant to exacting ISO 9001 discipline all boilers carry full CE marking of approval Technical sales and commercial service are available throughout the UK This product is guaranteed by The White Boiler Company Chartists Way Morley LEEDS LS27 9ET Telephone No 0113 252 7007 BASIC COMPONENTS See figure 1 Guarantee is a full 12 months from date of purchase providing the appliance has been fitted in accordance with these instructions and relevant codes of practice MAJOR COMPONENTS Gas valve Variable head pump suitable for any type of central heating system Burner with flame stabiliser designed to operate under all thermal conditions Primary heat exchanger constructed from stainless steel Unique patented condensing heat exchanger for high thermal flue transfer gases to water Stainless steel plate heat exchanger for super high heat transfer to domestic hot water supply Built in frost prote
104. e 21 Sensing electrode 22 Flue temperature sensor 23 Spark igniter 24 Fan 25 26 Manual air vent 27 Overheat cut off thermostat 28 CH flow sensor 29 CH return sensor 21 OPERATING SCHEME Fig 4 KEY 1 Flue exhaust manifold 2 Condensate drain 3 CH return 4 CH return sensor 5 Heat exchanger 6 CH flow 7 Overheat cut off thermostat 8 CH flow sensor 9 Manual air vent 10 Bumer 11 Spark electrode 12 Sensor electrode 13 Fan 14 Flue temperature sensor 15 Expansion vessel 16 Automatic air vent 17 Circulation pump 18 Water pressure transducer 19 Safety pressure relief valve 20 Diverter valve motor 21 Plate heat exchanger 22 DHW sensor 23 Gas valve 24 Gas service cock 25 CH compression ball valves 26 DHW compression ball valves INTRODUCTION This boiler is designed for the production of central heating and domestic hot water combined in one unit It is fitted with an automatic domestic hot water priority valve It is possible to select either a summer or winter function With the summer position only being for domestic hot water The winter position being for central heating with domestic hot water priority DESCRIPTION OF CONTROL SYSTEM AND SEQUENCE OF OPERATION Domestic hot water mode When the appliance is in rest mode select the
105. e Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls Service 1 Date Engineer Name Service 2 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service Date Engineer Name Service 4 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 5 Date Engineer Name Service 6 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Operative ID No Comments Comments Signature Signature Service 7 Date Engineer Name Service 8 Date Engineer Name Company Name Company Name Telephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature Service 9 Date Engineer Name Service 10 Engineer Name Company Name Company Name Tel
106. e as specified in clause sect 4 22 5 29 OUTDOOR SENSOR When controls external to the appliance are required design of the external electrical For use consult Outdoor Sensor circuits should be undertaken by a instructions competent person In accordance with the IEE wiring regulations 1 Remove the case 2 Check gas mains pressure at the gas valve test nipple upstream fig 35 with boiler operating sect 6 8 3 Adjust fan speed as sect 3 COMMISSIONING Each boiler has been through a rigorous operational testing procedure at our factory and should not require any further adjustment if you are not the installer but just commissioning this boiler check that the boiler has been installed in accordance with these instructions and the integrity of the flue system and the flue seals as described in the flue installation section GAS SUPPLY INSTALLATION Inspect the entire installation including the gas meter test for soundness and purge all as described in BS 6891 In Ireland refer to IS 813 2002 ELECTRICAL INSTALLATION Preliminary electrical systems checks to 6 5 ensure electrical safety shall be carried out by a competent person ALWAYS carry out the preliminary electrical system checks i e earth continuity polarity resistance to earth and short circuit using a suitable test meter INITIAL FILLING OF THE SYSTEM Open central heating flow and return valves Unscrew the cap on automatic air re
107. e central heating flow pipe to the operating the boiler isolating cock marked CHF Pipe dimensions and positions are marked on template supplied and fig 32 DOMESTIC HOT WATER Fig 31 The domestic hot water circuit does not need a safety valve but it is essential to ensure that the pressure of the cold water supply does not exceed 10 bar If in doubt it is advisable to install a pressure reducing valve The minimum pressure needed to operate the domestic hot water system is 0 5 bar with a flow of approx 3 Lts per min Flush out all foreign matter from the supply pipe before and after connecting to the appliance Connect the 15 mm cold water pipe to the appliance inlet Connect the 15 mm hot water pipe to the appliance outlet Gas service 15 mm Condensate drain connect 3 4 plastic only requires jubilee not supplied Central Heating flow CH 22mm Domestic Hot Water Pressure relief outlet DHW valve 15mm Domestic inlet water 15mm Central Heating return CH 22mm SAFETY VALVE DISCHARGE The safety valve is located to the rear 15 copper to permit a discharge pipe to be connected When connecting ensure the discharge pipe does not restrict access The discharge should terminate facing downward exterior to the building in a position where discharging possibly boiling water amp steam will not create danger or nuisance in easily visible position and not to cause damage to elect
108. e details should be recorded on the Benchmark Service Interval Record and left with the householder COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk Heating and Hotwater Industry Council HHIC FLOWCHART FOR LEVEL AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER Important Preliminary Information on Checks The air gas ratio valve is factory set and must not be adjusted DURING COMMISSIONING If the boiler requires conversion to operate with a different gas family e g conversion from natural gas to LPG separate guidance is provided with the conversion kit supplied and this must be followed PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK The installation instructions must have been followed gas type verified and gas supply pressure gas rate checked as required prior to commissioning As part of the installation process ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that maximum flue lengths have not been exceeded and all guidance has been followed e g Gas Safe Register Technical Bulletin TB 008 where chimney flues are in voids The ECGA should be of the correct type as specified by BS 7967 Prior to its use the EC
109. e securely wrapped When servicing avoid inhalation by using a vacuum cleaner or in conjunction with other tools After handling wash hands and other exposed parts THE WHITE BOILER COMPANY use only high quality material for production of this product in an effort to protect the environment components should be re cycled TABLE OF CONTENTS INTRODUCTION DESCRIPTION AND SEQUENCE TECHNICAL DATA GENERAL REQUIREMENTS INSTALLATION COMMISSIONING SERVICING INSTRUCTIONS REPLACEMENT OF PARTS FAULT FINDING ELECTRICAL SYSTEM DIAGRAM SPARE PARTS BENCHMARK COMMISSIONING CHECKLIST DETAILS GENERAL LAYOUT ree 9 E Fig 1 KEY 1 Condensate drain 12 Diverter valve motor 23 Flue temperature sensor 2 Gas valve 13 CH retum 24 Heat exchanger 3 Gas inlet 14 Water pressure sensor 25 Overheat cut off thermostat 4 CH flow 15 Circulation pump 26 Sensing electrode 5 Drain point 16 Automatic air vent 27 CH sensor 6 Safety pressure relief valve 17 Condensate drain 28 Fan 7 DHW outlet 18 Expansion vessel 8 DHW sensor 19 Bumer manifold 9 Plate heat exchanger 20 Spark electrode 10 DHW flow detector 21 Commissioning manual air vent 11 DHW inlet 22 Spark igniter OPERATING SCHEME
110. e wall The terminal rubber must also be fitted fig 16 17 item 127 127 5 10 INTAKE EXHAUST TERMINAL COMPONENTS T EU IMPORTANT Please lubricate the internal part of the seals before fitting KEY 50 Flue flange 60 Fumes sample point 65 Flue manifold rubber seal 56 Rubber seal 100 61 STD flue exhaust duct 66 Securing screw 57 Elbow header 62 Terminal 67 Flue temperature sensor 58 Header gasket 63 Flue extension 69 Air sample point 59 Rubber seal 60 64 Flue exhaust duct extension 127 Terminal Rubber wall seal 5 11 IN LINE FLUE BEND AND FLUE EXTENSION 49 In line Flue Bend 56 Rubber seal 100 IN LINE FLUE BEND 59 Rubber seal 60 Measure the distance between the flue bends or 63 Air intake duct extension the flue terminal assembly The measurements 64 Flue exhaust duct extension should be taken from the outer edge of the flue and bend fig 18 6 59 5 12 VERTICAL FLUE INSTRUCTION ONLY Fig 19 20 21 SEE SECT 4 10 FOR PERMISSIBLE FLUE POSITION IN LINE FLUE BEND 1000 mm MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 90 BEND OBTUSE FLUE BEND 500 mm MUST BE DEDUCTED FROM OVERALL LENGTH FOR EACH 135 BEND The vertical flue kit is intended for use where L L 8m a horizon
111. e wall Lift the boiler on to the wall Fig 13 locating onto the fixing jig wall bracket Working above the boiler pull the flue exhaust duct towards the boiler in order to engage tube Fig 17 item 61 into its header Position flue into elbow header and push so as to locate inner and outer flue correctly ensuring good seal is made with rings Fit terminal rubber wall seal and if necessary terminal guard Extensions kits are available to order for flue extension of up to 7 metres total length Fig 18 Each extension length extends the pipe by approximately 1000 mm long up to a maximum of seven extensions Pipeline length can be established using the instructions in section 5 5 for rear flue outlets and section 5 6 for side flue outlets Extensions must be installed with the widened end of the air intake pipe and the tapered end of the flue pipe aimed towards the exhaust terminal dr Recomended 268mm right only INSTALLING THE APPLIANCE FOR SIDE FLUE OUTLET Fig 14 15 16 17 18 19 Attach the template to the wall with adhesive tape making sure that the centre line is vertical and that the distance from the centre line to the nearest side wall is not less than measurement in Fig 14 Mark the two fixing bracket securing holes on the wall and extend the axis of the flue duct hole to the side wall ensuring it is horizontal Make sure flue slopes 1 5 down towards the boiler that is
112. eat input NOTE TO THE INSTALLER COMPLETE THE BENCHMARK COMMISSIONING CHECKLIST AND LEAVE THESE INSTRUCTIONS WITH APPLIANCE Burner operating pressure Central heating flow temp measure and record Central heating return temp measure and record For combination boilers only Scale reGUCEL Hot water mode Max operating burner pressure measure and record Max operating water pressure measure and record Cold water inlet temp measure and record Hot water temp measure and record Water flow rate at max setting measure and record For condensing boiler only Condensate drain For all boilers complete sign amp hand over to the customer THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS For assistance please call The White Boiler Company technical helpline telephone 0113 252 7007 fax 0113 238 0229 e mail sales ravenheat co uk Code Of Practice For the installation commissioning and servicing of domestic heating and hot water products Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations Ins
113. end of the extension connects to the boiler The flue output and air intake pipes fits into the boiler header until it stops Fig 17 Fig 18 NOTE a suitable support bracket is available from The White Boiler Company and should be used to support flue length at least every one metre preferably at each joint this bracket should be secured to wall and flue duct COMPLETING BOILER INSTALLATION lt Take off Reassemble the outer casing sect 5 4 in reverse order Securing screw lt Flue duct Air duct AME Flue adapter ubber seal 60 100 mm ecuring screws 90 bend IN LINE FLUE BEND Measure the distance between the flue bends or the flue terminal assembly The measurements should be taken from the outer edge of the flue and bend Fig 19 IMPORTANT inline flue bend 1000 mm must be deducted from overall length for each Obtuse flue bend 500 mm must be deducted from overall length for each 135 bend Table 3 page 19 INTAKE AND EXHAUST TERMINAL COMPONENTS E KEY 56 Flue adapter 61 STD flue exhaust duct 57 Elbow header 62 Terminal 58 Header gasket 63 Flue extension 59 Rubber seal 60 64 Flue exhaust duct extension 60 Fumes sample point 65 Flue manifold
114. ephone No Telephone No Gas Safe Register No Gas Safe Register No Comments Comments Signature Signature
115. er duct are square and to the same length SIDE FLUE OUTLET Drilling template 1 5 inclined min 125 mm The position of the appliance must provide Fixing bolts and minimum side clearances of 5mm as the wall plugs side panels do not require removing for servicing However if the option is preferred to remove the panels then a minimum clearance of 55mm is required Lower securing position if required PA min 195 Mm All joints must be sealed with the rubber seals supplied 15 important to put the centering spacer supplied with the unit inside between the two pipes from the side opposite the extension s straight end NOTE A suitable support bracket flue bracket is available from The White Boiler Company and 5mm to 55mm each TE side see note above should be used to support the flue length least every one metre preferably at each joint this bracket should be secured to wall and flue duct 450 mm front boiler minimum lI 5mm to 55mm each MN side see note above 80 mm 150 mm preferred Must be sealed COMPLETING HORIZONTAL FLUE INSTALLATION Must be sealed Ensure the flue system has been checked for soundness is stable and secure Where the horizontal flue terminal passes through the external wall it is essential that the flue must be sealed on both in exterior and interior part of th
116. er must be in accordance with the relevant recommendations of BS 5546 Copper tubing to BS 2871 1 is recommended for water carrying pipework and MUST be used for pipework carrying potable water ELECTRICAL SUPPLY Warning this appliance must be earthed External wiring to the appliance must be carried out by a competent person and be in accordance with the current Regulations and local regulations which apply The White Boiler Company boiler is supplied for connection to a 230 V 50 Hz single phase supply The supply must be fused at 3 A NOTE The method of connection to the electricity supply MUST facilitate complete electrical isolation of the appliance by the use of a fused double pole isolator having a contact separation of at least 3 mm in all poles The point of connection to the electricity supply must be readly accessible and adjacent to the appliance except where the appliance is installed in a bathroom When the currentelectrical wiring regulations must be followed in GB the IEE Wiring Regulations and in IE the ETGI Rules 18 Fig 9 5 1 5 1 1 5 2 5 2 1 5 3 5 3 1 5 3 2 5 4 5 4 1 5 4 2 5 4 3 SECTION 5 INSTALLATION WARNING It is MOST IMPORTANT that this appliance is installed in a VERTICAL POSITION with the flue air duct passing through the wall Make sure the flue is at a 1 5 incline rising from the b
117. eseaJoul ysnw Aue eu s y Jeioq y perddns suononujsui uonejjejsui eu 0 J9je1 eseeld SONY ejuozuou 001 en 4 Joy e qejeAe syy UeJBeip SIU uo UMOUS se peurejureui si seseo 06 peseeJoep eq ues Aue y y si swnd ji 10 FLUE TERMINAL POSITION 4 PIPEWORK Copper tubing to BSEN 1057 1 2006 BSEN 1172 BSEN 1652 and BSEN 1653 is recommended for water pipes Jointing should be either with capillary soldered or with compression fittings Where possible pipes should have a gradient to ensure air is carried naturally to air release points and water flows naturally to drain taps It should be ensured as far as possible that the appliance s heat exchanger is not a natural collecting point for air except where providing useful heat Pipes should be insulated to prevent heat loss and to avoid freezing Particular attention should be paid to pipes passing through ventilated spaces in roofs and under floors IMPORTANT A minimum length of 1 metre of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping The water through the appliance heat exchanger circuit must e
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119. f commissioning or Servicing work Refer to the manufacturer s helpline where assistance is needed Report product faults and concerns to the manufacturer in a timely manner Customer Service Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request Give a full and clear explanation demonstration of the product or system and its operation to the customer Hand over the manufacturer s instructions including the Benchmark Checklist to the customer on completion of an installation Obtain the customer s signature on the Benchmark Checklist to confirm satisfactory demonstration and receipt of manufacturer s instructions Advise the customer that regular product servicing is needed in line with manufacturers recommendations to ensure that safety and efficiency is maintained Respond promptly to calls from a customer following completion of work providing advice and assistance by phone and if necessary visiting the customer Rectify any installation problems at no cost to the customer during the installer s guarantee period www centralheating co uk INSTALLER NOTIFICATION GUIDELINES A change to Building Regulations England and Wales requires the installer to notify when installing a heating appliance as from 1st April 2005 Install and commission this appliance to manufacturer s instructions Complete the Benchmark Checklist Competent pe
120. gas rate The combustion performance COMPETENCE TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE Please note BS6798 2009 Specification for installation and maintenance of gas fired boilers of rated input not exceeding 70 kW net advises that The person carryng out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN 50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts 110 4 7 1 SERVICE INFORMATION FUNCTION When the jumper JP16 is inserted Co Control is displayed on the digital display fig 33 no water or heating led are ON only the yellow led is ON when boiler is running In summer position with DHW operating it is possible to set the minimum power by R10 trimmer Fig 39 In winter position with heating operating it is possible to set the maximun CH power by 9 trimmer In DHW operation it is possible to set the maximum DHW power by R19 trimmer Moving the knob of a trimmer the fan speed is displayed flashing for 10 seconds on the digital display see Technical data section 3 tables 5 A and 5 B page 34 and f
121. gital clock in demand position The ignition control will automatically make three attempts to start if it doesn t start this may be due to air in the gas supply line If the burner fails to light the digital led display and fan will stop and the display will show the lockout code E1 depicts flame failure If necessary push the boiler Reset button item 2 fig 1 and the boiler will restart automatically After the boiler has lit allow to warm at minimum temperature setting to purge any air from the system Once the system has been purged of air set the heating temperature to the desired setting CHECK THE GAS PRESSURE Check the gas mains pressure at the gas valve inlet pressure test point fig 35 with the boiler operating at full rate Check with the Local Gas supplier if the pressure differs significantly from 20 mbar G20 natural gas 37 mbar G31 propane and 29 mbar G30 butane With leak detection fluid test for gas tightness of all gas components and joints IMPORTANT The Gas Valve Throttle adjuster is required to be sealed with tamper proof paint after adjustment fig 35 COMBUSTION CHECK Check all gas carrying components along with the combustion of the appliance which should be checked as follows Remove the front panel of the appliance Ensure the boiler and external controls are calling for heat Turn on the electrical supply open the hot water tap at maximum flow rate Wait at le
122. he cap on automatic air release valve positioned on the top of the pump housing one full turn leave open permanently Close all air release taps on the central heating system Gradually open stopcock at the filling point connection to the central heating system until water is heard to flow Starting with the lowest radiator open each air release tap in turn Close it only when clear water free of bubbles flows out In the same way release air from any high points in the pipework Open the manual air vent at the boiler heat exchanger flow pipe see fig 30 may require repeating to assist commissioning GAS VALVE Outlet gas pressure test Inlet gas pressure test Throttle Fig 34 Continue filling the system until 1 5 bar register on gauge Then turn off the filling points stopcock Inspect the system for water soundness and remedy any leaks discovered SETTING THE HEATING SYSTEM DESIGN PRESSURE The design pressure must be a min 1 bar and max 1 5 bar These figures are read off the pressure gauge The actual reading should ideally be 1 bar the height in metres to the highest point of the system above the base of the appliance up to max of 1 5 bar N B The safety valve is set to lift at 3 bar 30 mt 42 5 psi To lower the system pressure to the required value remove at the drain point fig 35 or drain on the heating circuit
123. he competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission according to the manufacturer s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights Customer Telephone Number Address Boiler Make and Model Commissioned by print name Safe Register Number Company Telephone Number Company Address ee Commissioning Date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS Tick the appropriate boxes Time and Temperature Control to Heating Room Thermostat and Programmable Load Weather Optimum Start Programmer Timer Room Thermostat Compensation L Control Time and Temperature Control to Hot Water Oylinder Thermostat and Programmer Timer Combination Boiler Heating Zone Valves Not Required Hot Water Zone Valves Not Required Thermostatic Radiator Valves Not Required Automatic Bypass to System Not Required _ Boiler Interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions Yes What system cleaner was used What inhibitor was used Quantity litre
124. ial that all external controls are VOLT FREE Factory fitted internal wiring must not be disturbed when wiring external controls To gain access to the electrical box remove the front panel of the case as described in clauses sect 8 1 4 You can slide towards the top the instrument panel box and push the retaining latches and remove the instrument panel Sec 8 19 Heat resistant flexible cable is fitted between the isolator and the terminal block A 3 core cable of 0 75 mm 24x0 2 mm to BS 6500 Make sure all wires to the appliance are routed away from sharp edges and hot surfaces The cable must be fastened with its cord anchorage and connected so that should the cable slip from the anchorage the current carrying conductors become taut before the earthing conductor Securely tighten all terminal screws and arrange the cable with slack between the cord anchorage and the terminal block WARNING If the supply cord is damaged it must be replaced by a service engineer supply cord available from The White Boiler Company PROGRAMMABLE TIMECLOCK Instructions for use consult User s Guide OUTDOOR SENSOR For use consult Outdoor Sensor instructions POSITION OF WATER AND GAS CONNECTIONS DOMESTIC CONNECTIONS COMBI BOILER Drill wall if required N Relief valve DHW inlet CH return Gas inlet 15 mm 15 22 mm DHW outlet Condensate drain INSTRUMENT PANEL Timeclock Timer reset optiona
125. ig 39 7 2 SEQUENCE HISTORY CODES It is possible to see up to the last ten sequence of events on the digital display by pushing the reset button for 10 seconds In this case when the function is enabled the 3 leds on the panel start flashing Pushing the reset button again it is possible to view the others codes up to a maximum of ten After the tenth push the reset button to repeat the history Exit from history is automatic after 10 seconds The sequence history starts after 1 hour of first continuous power onto the board 7 3 BOILER FROST PROTECTION The appliance has built in frost protection device that protects the boiler from freezing With the gas and electric supplies ON and irrespective of any room thermostat setting the frost protection device will operate the pump when the temperature falls below 10 C and will operate the burner when the temperature falls below 5 C The burner will switch off when the temperature reaches 27 C When the frost protection device operates AF is displayed on the digital display IMPORTANT NOTE The system should be protected by incorporating a system frost thermostat To ensure continued efficient operation of the appliance it is necessary to carry out servicing and cleaning at regular intervals The frequency of cleaning will depend upon the particular installation conditions and usage but in general once a year is advisable WARNING Before the start of any servi
126. in flue it must be stated for WH 100 130 range Typical installation procedures are illustrated by drawings Remove the front panel of the case sect 8 1 Unscrew the screw Fig 17 item 66 on the flue adapter Make sure that the Flue manifold rubber seal is locate into the flue manifold and lubricate the internal part of the seal before assembly Locate the header gasket on the twin flue header and push into the flue adaptor Fig 17 item 56 making sure that the inner plastic exhaust locates firmly in the outlet spigot of the flue manifold and screw the securing screw that secure the twin flue header on the boiler Locate the 2 x 80 mm O rings in the twin flue header and lubricate the internal part of the seal before assembly to ensure easy snug fit Figures show the versatility of this flueing system Measurements and bends must be calculated correctly so as not to oversize maximum flue lengths All located O rings must be lubricated with a silicone grease to ensure easy snug fit NOTE Exhaust flue must slope 1 5 down towards the boiler 25 mm m fall per metre of flue length Spacing Clips Spacing Clips are available on request should they be required NOTE for eccentric vertical flue a 125 mm 5 in diameter flashing plate will be required IMPORTANT See Fig 5 for terminal clearances Vertical The pressure loss see table 3 Standard Flue Kit 1100mm Must NOT be shortened IMPORTANT NOTICE
127. ing bracket Working above the boiler pull the flue duct towards the elbow in order to engage the tube into its header Fig 10 Position flue into straight header and push so as to locate inner and outer flue correctly Ensuring good seal is made with O rings IMPORTANT Terminal rubber wall seal must When cutting both inner and outer ducts of the extension always ensure that the reduced end male of the inner and outer duct are square and to the same length All joints must be sealed with the rubber seals supplied Itisimportantto putthe centering spacer supplied with the unit inside between the two pipes from the side opposite the extension s straight end be fitted Fig 10 item 127 Each extension length extends the pipe by approximately 1000 mm long to maximum of seven extensions Pipeline length can be established using the instructions in section 5 5 for rear flue outlets and section 5 6 for side flue outlets Extensions must be installed with the widened end of the air intake pipe and the tapered end of the flue pipe aimed towards the exhaust terminal Extensions must be joined together with the standard terminal pipe and inserted in each other as far as they can go If an extension must be shortened this must be done from the straight end and not from the widened or tapered end To measure the pipeline properly all components must be assembled and total length measured before cutting The straight
128. ioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission according to the manufacturer s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights Customer name Telephone number Address Boiler make and model Boiler serial number Commissioned by PRINT NAME Gas Safe register number Company name Telephone number Company address Commissioning date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS tick the appropriate boxes Room thermostat and programmer timer Programmable room thermostat Time and temperature control to heating Load weather compensation Optimum start control Time and temperature control to hot water Cylinder thermostat and programmer timer Combination Boiler Heating zone valves Fitted Not required Hot water zone valves Fitted Not required Thermostatic radiator valves Fitted Not required Automatic bypass to system Fitted Not required Boiler inte
129. ir vent from the pump Replace in reverse order NOTE Always use new O ring Automatic air vent retaining clip Pump retaining clip Alternative drain point TO REMOVE REPLACE SAFETY RELIEF VALVE Fig 47 Remove front and bottom panels fig 39 40 Close the on off valves for C H circuit and drain the water from at drain point fig 36 Unscrew the safety relief valve screw and pull up Replace in reverse order and using a new gasket TO REMOVE REPLACE D H W SENSOR Fig 47 Remove front and bottom panels fig 39 40 Close the on off valve for the DHW circuit and drain the hot water from the lowest hot water tap Detach the wire connector and unscrew the sensor Replace in reverse order TO REMOVE REPLACE C H FLOW AND RETURN SENSORS Fig 49 Remove front panel fig 39 Detach the wire connector and remove the retaining clip sensor from the pipe NOTE When reconnecting ensure the correct wires go to the relevant sensor the polarity on each one is unimportant TO REMOVE REPLACE FLUE SENSOR Fig 3 item 22 Remove front panel fig 39 Detach the wire connector and rotate the sensor Replace in reverse order Overheat thermostat C H flow sensor clip C H return sensor
130. it the draining of the whole system The taps must be at least 15 mm nominal size and manufactured in accordance with BS 2870 1980 Heating System Heating System RETURN FLOW By pass Drain tap AIR RELEASE POINTS These must be fitted at all high points where air will naturally collect and must be sited to facilitate complete filling of the system The appliance has an integral sealed expansion vessel to accommodate the increase of water volume when the system is heated Additional expansion vessel if required It can accept up to 7 Its of expansion water If the appliance is connected to a system with an unusually high water content calculate the total expansion see table 4 and add additional sealed expansion capacity as appropriate Fig 7 In general modern systems below 7 Its should not present any problem MAINS WATER FEED CENTRAL HEATING There must be no direct connection to the mains water supply even through a non return valve without the approval of the Local Water Authority t 4 Supply pipe Return pipe PERMISSIBLE METHODS OF FILLING Figure depicts the requirements of Diagram R24 2a of the Water Supply Water Fittings regulations 1999 Filling loop Control valve Control valve
131. ith boilers If required DESTINATION AT DK SE amp GR CATEGORY 12 DESTINATION GB IE CH ES IT PT amp GR CATEGORY 12 FLUE TYPE Cis Cas NO 5 SEDBUK SECTION 4 GENERAL REQUIREMENTS 4 1 SAFETY Gas Safety Installation and Use Regulations It is law that all gas appliances are installed and serviced by a Gas Safe registered installer in accordance with the above regulations and these installation instructions All registered installers carry a Gas Safe 1 0 card and have a registration number Both should be recorded in your Benchmark commissioning checklist You can check your installer on the Gas Safe register Failure to install appliances correctly could lead to prosecution It is in your own interest and that of safety to ensure the law is complied with Check the boiler and flue is the correct type for installation The installation of the boiler MUST be in accordance with the latest BS 7671 Wiring Regulations local building regulations bye laws of the local water authority the building regulations and the Building Standards Scotland and any relevant requirements of the local authority GENERAL INFORMATION Both the user and the manufacturer rely heavily on the installer whose job it is to install the combination boiler and connect it to a correctly designed heating system Acquaint yourself with the relevantBritish Standards concerning installation requirements If you
132. l Pressure gauge Central heating Boiler reset Led ON boiler CH mode Led ON boiler DHW mode Led ON burner ON Digital display Domestic Hot water Central heating control knob control knob Central switch main Summer winter switch Summer winter switch C C I Summer position Winter position Hot water only Central heating and hot water SECTION 6 COMMISSIONING 6 1 Each boiler has been through a rigorous operational procedure at our factory and should not require any further adjustment if you are not the installer but just commissioning this boiler check that the boiler has been installed in accordance with these instructions and the integrity of the flue system and the flue seals as described in the Flue installation section GAS SUPPLY INSTALLATION Inspect the entire installation including the gas meter test for soundness and purge all as described in BS 6891 In IE refer to IS 813 2002 ELECTRICAL INSTALLATION Preliminary electrical systems checks to ensure electrical safety shall be carried out by a competent person ALWAYS carry out the preliminary electrical system checks i e earth continuity polarity resistance to earth and short circuit using a suitable test meter INITIAL FILLING OF THE SYSTEM Open central heating flow and return valves Unscrew t
133. l display IMPORTANT NOTE THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Combustion testing must be carried out by competent person using a combustion analyser conforming to BS7927 The system should be protected by Incorporating a system frost thermostat During routine servicing and after any maintenance or change of part of the combustion circuit the following must be checked The integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals The operational dynamic working gas inlet pressure at maximum rate The gas rate The combustion performance Refer to table 10 and page 63 Check all joints and connections in the appliance and remake any that show signs of leakage NOTE Service consumables are not covered by the warranty To view warranty exclusions please visit www ravenheat co uk or contact us on 01132 527007 COMPETENCE TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE Please note BS6798 2009 Specification for installation and maintenance of gas fired boilers of rated input not exceeding 70 kW net advises that The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN 50
134. lace condensing trap To remove panel control box To remove the instrument panel To remove replace control board To remove replace digital display board External control connection Fault finding Central heating Fault finding Domestic Hot Water Electrical system diagram 1 USERS GUIDE It is the law that all gas appliances are installed by a competent person in accordance with the gas safety installation and to the current Gas Safety Installation and Use Regulations B S 5440 2 2000 All registered installers carry a Gas Safe Register ID card and have a registration number Both should be recorded in your boiler Log book You can check your installer s registration at www gassaferegister co uk COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS ESCAPE OF GAS Should a gas leak be suspected contact your gas supplier without delay GAS EMERGENCY NUMBER 0800111999 Do NOT search for gas leaks with a naked flame WARNING This appliance must be earthed 11 INTRODUCTION Please carefully read the information given in this booklet to help you gain maximum control from your appliance with minimum trouble and cost Your White Boiler Company Condensing Low Nox combination boiler has been designed to supply your Central Heating and Domestic Hot Water directly from one unit When Central Heating is operating the circulation will be interrup
135. le from the back of the boiler The boiler must not be fitted outside LPG versions of this appliance shall not be installed in cellars or basements CLEARANCES AROUND THE APPLIANCE Side clearance The position of the appliance must provide a minimum clearance of 5mm as the side panels do not require removing for servicing However if the option is preferred to remove the panels then a minimum clearance of 55mm is required Top clearance The top clearance should be a minimum of 125 mm Bottom clearance A bottom clearance of 80 mm is required between the appliance and any surface Though 150 mm is preferred whenever possible Front clearance A minimum of 450 mm is required in front of the appliance for access during servicing the front clearance can be reduced when installed in a cupboard to 25 mm from the access door IMPORTANT NOTICE For installation into timber framed buildings please refer to the Institute of Gas Engineers Document IGE UP 7 The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current 1 Wiring Regulations and in Scotland the electrical provisions of the Building Regulations applicable in Scotland with respect to the installation of the combination boiler in a room or internal space containing a bath or shower Where a room sealed appliance is installed a room containing a bath or shower any electrical s
136. lease valve positioned on the top of the pump housing one full turn leave open permanently Close all air release taps on the central heating system Press the P button to display the current pressure code E8 will display if the pressure is nil too low Gradually open stopcock at the filling point connection to the central heating system until water is heard to flow Starting with the lowest radiator open each air release tap in turn Close it only when clear water free of bubbles flows out In the same way release air from any high points in the pipework Continue filling the system until 1 5 bar register on digital display Press the P button once again to return to the main screen GAS VALVE Throttle Adjust with a4 mm Allen key Inlet test point Use a Star key T15 Then turn off the filling points stopcock Inspect the system for water soundness and remedy any leaks discovered SETTING THE HEATING SYSTEM DESIGN PRESSURE The design pressure must be a min 1 bar and max 1 5 bar These figures are read on the digital display by pressing the P button The actual reading should ideally be 1 bar the height in metres to the highest point of the system above the base of the appliance up to max of 1 5 bar N B The safety valve is set to lift at 3 bar 30 mt 42 5 psi To lower the system pressure to the required value remove at the drain point fig 36 or drain on the heating circuit
137. liance is designed to operate with the minimum of ease for the user All the controls are found on the control panel on the front of the boiler OPERATING SAFETY CHECKS TO PROTECT YOUR APPLIANCE CHECKING THE SYSTEM PRESSURE Before lighting the appliance check that the Central Heating system pressure is not less than 1 bar If it is below this it will be necessary to re pressurise the system between 1 and 1 5 bar to allow the boiler to operate To view the system pressure press the P button once this will display the current pressure if the pressure is on nil or too low then error code 15 displayed A filling device filling loop will have been fitted on the system This is usually on the pipework near to the boiler If you are unsure of its position or you cannot identify it consult the installer who fitted the boiler The filling loop usually consists of two taps and a separate silver coloured braided flexible pipe with connection fittings Only when re pressurising should the braided flexible pipe be connected between the two taps ensure that the nuts or the pipe ends are tightened onto the taps Fully open one of the taps first and then while monitoring the water pressure on the digital display carefully open the second tap When the water pressure is toa maximum of 1 5 bar turn both taps off Disconnect the flexible pipe from the taps a small amount of water may be present Keep the pipe in a safe place for f
138. lp It is recommended that tools suitable for brass fittings are used and have a capability to accommodate hexagon sizes up to 50 mm APPLICIBLE CODES OF PRACTICE Ref Documents Detailed recommendations are containedin the following British Standard Codes of Practice BS6891 2005 Low pressure installation pipes BS6798 Installation of gas fired hot water boilers of rated input not exceeding 70 kW BSEN12828 Design for water based heating systems BSEN12831 Heating systems in buildings Method for calculation of the design heat load BSEN14336 Installation amp commissioning of water based heating systems BS5546 Installation of gas hot water supplies domestic purposes 2nd Family Gases BS5440 Flues for gas appliances of rated input not exceeding 70 kW BS5440 2 Ventilation for gas appliances of rated input not exceeding 70 kW BSEN 677 1998 Gas fired central heating boilers 1 5 813 Domestic gas Installations The followings standards give valuable additional information BS 7074 Expansion vessels and ancillary equipment for sealed water system BS 7593 Treatment of water in domestic hot water and central heating system Health amp Safety Document No 635 The Electricity at Work Regulations 1989 IMPORTANT These appliances are CE certificated for safety and performance It is therefore important that no external control devices e g flue dampers economisers etc are directly
139. lways start at the Set point speed The boiler is fitted with an anti cycling device on the control board This delays the boiler from re firing within 10 minutes If the heating temperature goes 20 below the set point the burner restarts immediately The domestic hot water will always take priority and is unaffected by the anti cycling device GENERAL FUNCTION The instrument panel permits regulation of the boiler to partial heating requirements between maximum and minimum settings Air and gas are drawn by the fan for combustion The fan also forces exhaust gas through the flue to the outside this creates a lesser pressure in the sealed combustion chamber thus sucking in combustion air through the inlet duct The boiler water temperature is automatically controlled by a built in thermostat Interior space temperature is set by the room thermostat to be installed in the heating system The boiler already carries connection terminals for this thermostat as well as for a external timer if required The burner continues to operate until it is stopped by the digital clock or one of the thermostats When the internal C H temperature sensor or the room thermostat intervenes the burner shuts down The fan stops but the pump continues to operate for 3 minutes The boiler also incorporates an anti block system which powers the pump every 24 hours allowing it to operate for 2 minutes if the boiler has not been in use
140. ments ELECTRODES POSITION N Ignition electrode Sensing electrode Heat exchanger 41 ATTENTION IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED AND LEFT WITH THE APPLIANCE Denchmar THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Once the process of commissioning the boiler is complete the commissioning engineer MUST complete the relevant section in the Benchmark log book CHECKING THE FLUE SYSTEM The flue system should be visually checked for soundness Check all connections and fixings are secure and tight CHECKING THE HEATING THERMOSTAT Allow the system to warm up and then select the C H thermostat to ensure the main burner modulates from high to low and low to off and vice versa scale range covers approx 35 C 80 C sec 1 5 key 5 to set heating temperatures TESTING AND REGULATING THE DOMESTIC HOT WATER SYSTEM FLOW AND CHECK THE OPERATIONAL WORKING INLET PRESSURE Set up the boiler to operate at maximum rate by opening the hot tap to maximum flow With the boiler operating at the maximum rate check the operational dynamic working gas pressure test complies with the requirements Ensure that this inlet pressure can be obtained with all other gas
141. ming is causing a nuisance or can be used to eliminate condensate collecting on the end of the horizontal flue terminal L L max 6000 mm minimum plume kit length 500 mm i v e INSTALLING THE APPLIANCE FOR REAR FLUE OUTLET Fig 13 15 16 17 18 19 FOR APPLIANCE CLEARANCES SEE 4 3 1 AND FIG 5 Use adhesive tape to attach the template to the wall making sure that the centre line is vertical and that the distance clearance is no less than that shown in Fig 13 FIXING JIG WALL BRACKET 187mm min 125mm 105mm Mark the two holes to fix the hanging bracket on the wall as WALL PLUG well as the centre of the flue duct Detach the template from the wall Use a 10 mm dia drill to make the 2 holes Insert the plastic expansion plugs Cut or core drill 105 mm dia hole for inserting the flue duct Locate the wall hanging bracket and fix using the two coach bolts Fit the elbow header positioning it towards the required direction Fig 13 onto the boiler Make sure that the rubber 60 is locate into the flue elbow header If using horizontal flue duct and it is too long it can be shortened Should it be necessary to cut the flue always Cut equal amounts from both inner and outer pipes Note add 30 mm to overall flue length to allow for terminal wall cover Fig 10 item 127 Insert the flue assembly into th
142. move the 2 screws that secure the spark igniter to the bracket Replace in reverse order Unscrew the two screws and pull left side 3 Unscrew the four screws and remove only the right screws 2 Remove the retaining clip 1 Unscrew the nut d Remove the front panel Remove the bottom panel 4 Pull right side the fan and pull forward TO REMOVE REPLACE FAN Fig 42 Remove front panel fig 39 Unscrew the gas pipe nut and remove the retaining clip Detach the connectors from the fan Unscrew the four screw that fix the fan and remove only the right screws Pull the fan to the right and pull forward Replace in reverse order always fitting a new gasket TO REMOVE REPLACE THE ELECTRODES Fig 37 Remove front panel fig 39 Remove the ignition and or sensing lead plug Unscrew the two securing screws and put them into a suitable container so that they don t get lost Withdraw the Spark electrode and or sensing electrode carefully from the burner cover being careful not to damage the seal Replace with a new electr
143. n the top of the boiler Ter Tee F Sr Vertical standard Vertical standard r Vertical standard Vertical standard flue kit 1100mm flue kit 1100mm flue kit 1100mm flue kit 1100mm Must NOT be shortned Must NOT be shortned Must NOT be shortned Must NOT be shortned Collar Flashing Flashing Flashing Flashing plate N plate plate plate i Flat roof N Straight Flue Straight Flue 90 Offset Flue 135 Offset Flue 25 Max 25 20 22 5 plus Terminal plus Terminal plus Terminal plus Terminal NOTE If using Flue arrangement in Fig 28 then the 125x100 Flue reducer must be purchased separately PR5094110A Straight flue header sample point internal part of the seals before being fitted 60 100 PRO110300 Flue Extension 80 125 L1000 R
144. nchmark log book c White paper template d e Guarantee card Polythene bag containing 1 15 mm gas service valve 2 22 mm compression ball valves complete with 3 4 washers 1 15 mm compression ball valves complete with 1 2 washers 1 15 mm compression ball valve 2 fixing bolts and wall plugs IMPORTANT NOTES This appliance will produce a plume of condensation in cool weather This is due to the High Efficiency and hence low flue gas temperature of the boiler A plume management kit is available see section 5 6 fig 12 UNPACKING OF BOILER IMPORTANT With regard to the Manual Handling Operations 1992 Regulations the following lift operation exceeds the recommended weight for a one man lift Stand the boiler carton upright Open the top of the carton Rest the carton on the floor keeping the flaps open Turn the carton over with the boiler inside and then pull the carton up away from the boiler Rest the boiler on its back on the floor to prepare it for installation POSITIONING OF THE BOILER Unscrew the two lower screws that secure the front panel and pull forward and lift up fig 39 Unscrew the 4 screws that fasten the lower grating on the casing and remove it from the bottom of the casing Make sure the casing and screws are put to one side in a safe place 5 5 OPTIONAL EXTRAS HORIZONTAL FLUE KIT BOX CONTAINING IMPORTANT Please lubricate the Fig 1
145. nd ensure that there is no obstruction Examine the gasket at the entry into the flue manifold It is essential that a good seal is made at the outlet to the flue manifold renew this gasket if there is any sign of damage or deterioration REPLACEMENT OF PARTS GENERAL Replacement of parts must be carried out by a competent person Before replacing any parts the boiler should be isolated from the mains electric supply and the gas should be turned off at the service cock on the boiler After replacing any parts always test for gas soundness and if necessary carry out functional test of the controls For replacement of parts the front and bottom panels of the boiler will need to be removed it is not necessary to remove the side panels as all parts are accessible from the front or beneath the boiler TO REMOVE THE BOILER PANELS To remove the front panel unscrew the two lower screws that secure the front panel to the boiler and lift off To remove the bottom panel unscrew the four screws and lift off Unscrew the screws pull forward and lift up TO REMOVE LEFT AND RIGHT PANELS Fig 40 Remove front panel fig 39 Unscrew the four screw to the bottom panel Unscrew the two screws to the side panel rotate 48 mm and unhook Rotate 48 mm and pull down TO REMOVE REPLACE SPARK IGNITER BOX Fig 41 AC Remove front panel fig 39 Detach all the connectors from the igniter control box Re
146. ne with the flue and push so as to locate inner and outer flue correctly Ensuring a good seal is made with O rings Tighten the two screws on the flue flange to secure the elbow header in place IMPORTANT Terminal rubber wall seal must be fitted item 127 fig 10 Each extension length extends the pipe by approximately 1000 mm long up to a maximum of seven extensions Pipeline length can be established using the instructions in section 5 5 Extensions must be installed with the widened end of the air intake pipe and the tapered end of the flue pipe aimed towards the exhaust terminal NOTE The position of the appliance must provide minimum side clearances of 5mm as the side panels do not require removing for servicing However if the option is preferred to remove the panels then a minimum clearance of 55mm is required Extensions must be joined together with the standard terminal pipe and inserted in each other as far as they can go If an extension must be shortened this must be done from the straight end and not from the widened or tapered end To measure the pipeline properly all components must be assembled and total length measured before cutting The straight end of the extension connects to the boiler The flue output and air intake pipes fits into the boiler header until it stops fig 17 18 When cutting both inner and outer ducts of the extension always ensure that the reduced end male of the inner and out
147. ng system Also check pipework and renew any corroded pipework or fittings Valve glands must be repacked or replaced wherever necessary Reference should be made to British Gas Publications Material Installation Specifications for Domestic Central Heating and Hot Water Draining taps should be at least 1 2 in BSP nominal size and be in accordance with BS 2879 Installation to an existing central heating system The combination boiler is designed to operate on a sealed system only Therefore if the existing system is of the open water type it will have to be modified to comply with BS 5376 Part 2 Before installing a new combination boiler to an existing system flush out the old system with a recommended descaling agent and any defective controls exchanged WATER TREATMENT This boiler has a aluminium and stainless steel heat exchanger The White Boiler Company recommended the use of FERNOX or SENTINEL or other treatment products recognised by The White Boiler Company which must be used in accordance with the manufacturers instructions 4 8 12 4 9 4 9 1 4 10 4 10 1 Inclined 1 5 min Hard water areas If the area of installation is recognized as hard water it is recommended that a suitable water treatment device is installed in the mains The water hardness can be determined by using the standard test paper or by referring to local water authority DOMESTIC WATER The domestic hot wat
148. nger called for the boiler will automatically return to the central heating mode Select summer winter switch Fig 33 in summer position The boiler functions like an automatic gas hot water heater When D H W is no longer required the burner and pump and fan immediately turn off This also takes place when the summer winter Switch is on winter if there is no demand for heat to the central heating system or until the timeclock demands for central heating circuit SAFETY DEVICE In both central heating and domestic hot water mode safe operation is ensured by a control board which shuts off the main burner if the fan stops or the flue or combustion air intake duct is obstructed An overheat cut off thermostat acts to turn off the burner to resetable lockout Fig 33 A safety valve is fitted on the central heating circuit set at 3 bar A low water pressure switch set at 0 4 bar is fitted on heating circuit to prevent the boiler operating below this boiler system pressure H AVAILABLE PUMP HEAD Fig 4a OVERALL DIMENSION Hm 300 PRESSURE DROP ACROSS APPLIANCE Fig 4b SECTION 3 TECHNICAL DATA TABLE 1 A WH 100 T NATURAL GAS 20 2 gt NOMINAL HEAT INPUT NET QMS MINIMUM HEAT INPUT NET NOMINAL HEAT OUTPUT
149. noo QOS pue J yore 92 1528 1e Jo eq JsNW suonoes e UOZIOY Iv uosued e ji punos6 y z uey 5501 ejqnsnquuoo uou S eui eq jeuiuue 005 JLA edid eyesuepuoo Y BIA jesodsip ejes 104 xoeq y 002 sea e eq 000 0 eyesuepuoo zey einsue 9 Jo unq seu aun eu sjonpoud dn Buiuedo eu uedo sepis 40 USA yodueo e ue jo epis MOPUIM JO JOOP Jeuye pue ay uo ue 0021 002 jou 3 LON y Buuejue sjonpoud uonsnquuoo 0j os peuonisod aq jsnu sjeuiuJej seoueijee o y jueuieunseaui 3 1 ON 00S jo ay jo 1sewo 002 Uey sse ou 5 uoneje sjeuiuuej ey Hed OPPS 58 eouesinu e
150. nquioo os peuorsod eq jsnui peJinbeJ y queuieJnseaui 3 LON MOPUIM oos N N TER A EEE SS SEAS 0 00 82 edid N N uoee sjeuiuuey 001 Jo ue 00 008 1 sjonpoud suonsnquioo jo dn eui enp e jo do eui 0001 uey eq jouueo 941 at Jo apis Jayla JO 009 000 MOPUIM Xh 9A QOS mous 1 10 jooJ peuoyd 00 o uu pos MODUIM 10 3 pue any Jeonje 0091 MOpUIM jeuuog ayeu uedo ue 006 40 any pejees WOO 009 Joo uo Aue eoueieej 009 eBpu apno ysneyxe 3 ejui 9 peurejuieui eq 006 Jo e uoojeq e y Bun jenno jsneuxe 1 sjy uo se peulejuleu si seseo QG peseaJoep eq Aue 0
151. nstall a pressure reducing valve The minimum pressure needed to operate the domestic hot water system is 0 5 bar with a flow of approx 3lts per min Flush out all foreign matter from the supply pipe before and after connecting to the appliance Connect the 15 mm cold water pipe to the appliance inlet Connect the 15 mm hot water pipe to the appliance outlet Gas service 15 8 Condensate drain connect 3 4 plastic only requires jubilee not supplied Pressure relief valve 15 mm Central Heating return CH 22 mm Condensate drain c 97 CH return 22mm SAFETY VALVE DISCHARGE The safety valve is located to the rear 15 mm copper to permit a discharge pipe to be connected When connecting ensure the discharge pipe does not restrict access The discharge should terminate facing downward exterior to the building in a position where discharging possibly boiling water amp steam will not create danger or nuisance an easily visible position and not to cause damage to electrical components or wiring The discharge must not be over an entrance or a window or any other type of access CONDENSATE DRAIN CONNECTION The condensate drain connection is a flexible 3 4 pipe and is therefore adjustable Fig 29 The drain pipe should have a fall of a least 2 5 away from the boiler Condensate should if possible be discharged into the household internal drainage system If this is not pra
152. nsure an adequate supply is available both to the boiler and the other appliances when they are in use at the same time FLUE SYSTEM The terminal should be located where dispersal of combustion products is not impeded and with due regard for the damage or discolouration that might occur to building products in the vicinity see fig 5 The terminal must not be located in a place where it is likely to cause a nuisance In cold and or humid weather as water vapour may condense on leaving the flue terminal The effect of such pluming must considered The terminal must not be closer than 25 mm 1 in to any combustible material For protection of combustibles refer to BS 5440 1 Where a flue terminal is installed less than 1000 mm from a plastic or painted gutter or 500 mm from painted eaves an aluminium shield 1000 mm long should be fitted to the underside of the gutter or painted surface be Pluming will occur at the terminal so where possible terminal positions which could cause a nuisance should be avoided The flue must be installed in accordance with the recommendations of BS 5440 Part 1 IMPORTANT NOTES For greater flue lengths see alternative flue instructions Flue must be positioned in a place not likely to cause a nuisance from pluming y uj pjnoo uosJed e ji 10 punoJD ay Woy z uey 5591 s eui J eq
153. ode in reverse order Ensure the gap is correct and there is a good seal when replaced always fitting a new gasket TO REMOVE REPLACE THE BURNER FIG 43 Remove front panel fig 39 Unscrew the gas pipe nut and remove the retaining clip Detach the connectors from the fan Unscrew the screws to the burner cover and remove the cover with the fan To remove the burner unscrew the screws in the lower cover side Replace in reverse order always fitting a new gasket 3 Lift up the fan with the burner cover and pull forward 2 Unscrew the four screws 1 Unscrew the nut Gasket Burner Unscrew the screws Fig 43 TO REMOVE REPLACE THE MAIN HEAT EXCHANGER Remove front and bottom panels fig 39 40 Drain the boiler CH circuit and drain the DHW circuit Follow the instructions to remove the burner sect 8 7 Pull down to remove the condense pipe on the bottom of the heat exchanger Disconnect the flow and return pipes at the heat exchanger Loosen the four heat exchanger securing screws and clamps then carefully ease the heat exchanger out CAUTION There will be water in the heat exchanger Replace in reverse order always use new O ring seals TO
154. oiler with 50 mm Flue terminal diagram states 1 5 25 mm fall back on flue see fig 5 DELIVERY The appliance carton contains a boiler fully assembled with flue adaptor b installation instructions user instructions and Benchmark log book c white paper template d hanging bracket e guarantee card f Polythene bag containing 2 22 mm compression ball valves complete with 3 4 washers 1 15 mm compression ball valves complete with 1 2 washers 1 15 mm compression ball valve 2 fixing bolts and wall plugs screws and dowels IMPORTANT NOTES This appliance will produce a plume of condensation in cool weather This is due to the High Efficiency and hence low flue gas temperature of the boiler See Optional extras Fig 12 UNPACKING OF BOILER IMPORTANT With regard to the Manual Handling Operations 1992 Regulations the following lift operation exceeds the recommended weight for a one man lift Stand the boiler carton upright Open the top of the carton Rest the carton on the floor keeping the flaps open Turn the carton over with the boiler inside and then pull the carton up away from the boiler Rest the boiler on its back on the floor to prepare it for installation POSITIONING OF THE BOILER Remove the 2 lower and the 2 upper screws that secure the front panel and then lift off Unscrew the 4 screws that fasten the lower grating on the casing and remove it from the bot
155. on commissioning and servicing of domestic heating and hot water products Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations Installers are required to carry out work in accordance with the following THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS The use of the word installer is not limited to installation itself and covers those carrying out installation commissioning and or servicing of heating and hot water products or the use of supporting products such as water treatment or test equipment Customer includes householders landlords and tenants Heating and Hotwater Industry Council HHIC Standards of Work Be competent and qualified to undertake the work required Install commission service and use products in accordance with the manufacturer s instructions provided Ensure that where there is responsibility for design work the installation is correctly sized and fit for purpose Meet the requirements of the appropriate Building Regulations Where this involves notifiable work be a member of a Competent Persons Scheme or c
156. onfirm that the customer has notified Local Authority Building Control prior to work commencing Complete all relevant sections of the Benchmark Checklist Service Record when carrying out commissioning or servicing of a product or system Ensure that the product or system is left in a safe condition and whenever possible in good working order Highlight to the customer any remedial or improvement work identified during the course of commissioning or Servicing work Refer to the manufacturer s helpline where assistance is needed Report product faults and concerns to the manufacturer in a timely manner Customer Service Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request Give a full and clear explanation demonstration of the product or system and its operation to the customer Hand over the manufacturer s instructions including the Benchmark Checklist to the customer on completion of an installation Obtain the customer s signature on the Benchmark Checklist to confirm satisfactory demonstration and receipt of manufacturer s instructions Advise the customer that regular product servicing is needed in line with manufacturers recommendations to ensure that safety and efficiency is maintained Respond promptly to calls from a customer following completion of work providing advice and assistance by phone and if necessary visiting the c
157. ons The combination boiler is designed to operate on a sealed system only Therefore if the It is recommended that you fit a primary existing system is of the open water type it will water cleanser to the system We have to be modified to comply with BS 5376 recommend fitting a filter that will help Part 2 remove both magnetite and non magnetic Before installing a new combination boiler to debris an existing system flush out the old system with a recommended descaling agent If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleaning and flushing out the old system with recommended descaling agent 4 19 WATER TREATMENT Inclined 1 5 min L This boiler has an aluminium and stainless steel heat exchanger The White Boiler Company recommend the use of FERNOX or SENTINEL or other treatment products recognised by The White Boiler Company which must be used in accordance with the manufacturer s instructions HARD WATER AREAS If the area of installation is recognised as a hard water area it is recommended that a suitable water treatment device is installed on the mains supply The water hardness can be determined by using the standard test paper or by referring to local water authority DOMESTIC WATER The domestic hot water must be in accordance with the relevant recommendations of BS 5546 Copper tubing to BS 2871 1 is recommended for water carrying
158. oom thermostat if fitted demands the central heating circuit SAFETY DEVICE In both central heating and domestic hot water mode safe operation is ensured by a control board which shuts off the main burner if the fan stops or the flue or combustion air intake duct is obstructed An overheat cut off thermostat acts to turn off the burner to resettable lockout item 8 fig 1 A safety valve is fitted on the central heating circuit set at 3 bar A low water pressure switch set at 0 4 bar is fitted on heating circuit to prevent the boiler operating below this boiler system pressure 2 9 AVAILABLE PUMP HEAD Fig 6 300 2 10 PRESSURE DROP ACROSS APPLIANCE Fig 7 3 TECHNICAL DATA WH 80 T NATURAL GAS 20 NOMINAL HEAT INPUT NET QMS 20 0 kW MINIMUM HEAT INPUT NET 3 7 kW NOMINAL HEAT OUTPUT 19 5 kW NOMINAL HEAT OUTPUT CONDENSING 21 4 kW MINIMUM HEAT OUTPUT 3 6 kW MINIMUM HEAT OUTPUT CONDENSING 4 0 kW GAS RATE 2 1 m h AFTER 10 MINUTES min 0 4 m3 h INLET PRESSURE 20 mbar FAN SPEED Max 4200 rpm 140 Hz Combustion CO 9 0 0 5 0 5 Case ON C H min 1300 rpm 43 Hz 9 0 0 5 0 5 Case OFF ELECTRICAL SUPPLY 230 50 2 POWER CONSUMPTION 110 W EXTERNAL FUSE RATING 3A INTERNAL FUSE F1 3 15A 20mm to BS 4265 DRY WEIGHT 28 kg WATER CONTENT C H 0 8 litre WATER CONTENT 0 2 litre
159. orizontal flue basament installations installations Use adhesive tape to attach the template to the wall making sure that the centre line is vertical and that the Fig 20 flue centre line is virtually below the point at which the flue will exit the roof F peer F Vertical standard Vertical standard Vertical standard Vertical standard flue kit 1100mm flue kit 1100mm flue kit 1100mm flue kit 1100mm Must NOT be shortned Must NOT be shortned Must NOT be shortned Must NOT be shortned Collar Flashing Flashing Flashing Flashing plate X 1 plate N plate N plate N pd 600 mm Flat roof Fig 21 Co Straight Flue Straight Flue Offset Flue Offset Flue L 12 0 m Max L 12 0 m Max L 10 m L 11m plus Terminal plus Terminal plus 2 bend 90 plus 2 bend 45 and Terminal and Terminal Ensure that the maximum permissable flue
160. pecifically for this purpose An existing cupboard or compartment may be used provided it is modified accordingly Samples of the WH 100 130 combi boiler have been examined by B G Technology Notified Body and is certified to comply with the essential requirements of the Gas Appliance Directive 90 396 EEC the Low Voltage Directive 72 23 EEC and shows compliance with the Electro Magnetic Compatibility Directive 89 336 and therefore permitted to carry the CE Mark 4 5 4 5 1 4 6 4 6 1 The appliance has been tested and approved by the WRc as meeting the requirements of G3 and L of the Building regulations and water Bylaws Scheme Approved Products GAS SUPPLY A gas meter is connected to the service pipe by the Local Gas Region or the Local Gas Region contractor An existing meter should be checked preferably by the Gas Region to ensure that the meter is adequate to deal with the rate of gas supply required for all appliances it serves Installation pipes should be fitted in accordance with BS 6891 Pipework from the meter to the boiler must be of adequate size 22 mm min to within at least one metre of the boiler 15 mm min can then be used for remaining pipe work to the appliance A smaller size than the boiler inlet gas connection should not be used The complete installation must be tested for soundness as described in the above Code N B if the gas supply for the boiler serves other appliances e
161. ral guidance The boiler MUST be installed so that the terminal is exposed to external air It is important that the position of the terminal allows the free passage of air across it at all times Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in section 4 10 Note positions Due to the terminal design installation is possible with clearances less than those specified in BS 5440 Part 1 NOTE The flue must be terminated in a place not likely to cause a nuisance A concentric vertical flue kit is available for longer flueing applications see table 5 page 26 For further details see vertical flue installation instructions AIR SUPPLY The following notes are intended for general guidance The room sealed fan flued boiler does not require a permanent air vent for combustion air supply Where installed in a cupboard or compartment ventilation is not required WATER CIRCULATION Central heating Detailed recommendations are given in BS6798 2009 5449 1990 BSEN12828 BSEN12831 BSEN14336 for smallbore and microbore central heating systems The following notes are given for general guidance QOL 09 eiqnsnquioo ojui eyesuepuoo eui pj
162. rd or sideways direction Although they are not substitute for a plume kit they can be considered useful where condensate pluming is causing a nuisance or can be used to eliminate condensate collecting on the end of the horizontal Maximum Length mm 6000 flue terminal minimum length 500 6000 mm flue extension duct as an Plume Management Kit TABLE 6 Equivalent length of 45 bend mm 500 Equivalent length of 90 bend mm 1000 The Maximum permitted flue length is measured from the centre line of the flue terminal to the top of the outlet terminal IMPORTANT Max flue length must not exceed 6 m with a horizontal concentric 60 100 flue of 3 m L Plume Management Kit Part No Part No Description TER110101 Fig 12 terminal bend metre high plume kit containing 1 1 90 elbow bend 1 metre 60 M F flue length 1 flue length bracket 1 n n n 2 45 bend n n LA L L max 6000 mm CUR110050 45 flue exhaust deflection bend minimum plume kit length 500 mm Fig 12a CUR110100 90 flue exhaust deflection bend Fig 12a IMPORTANT Please lubricate the internal part of the seals before fitting INSTALLING THE APPLIANCE FOR REAR FLUE OUTLET Fig 13
163. rical components or wiring The discharge must not be over an entrance or a window or any other type of access CONDENSATE DRAIN CONNECTION The condensate drain connection is a flexible 3 4 pipe and is therefore adjustable Fig 31 The drain pipe should have a fall of a least 2 5 away from the boiler Condensate should if possible be discharged into the household internal drainage system If this is not practicable discharge can be allowed into the external household drains or a purpose designed soak away It is recommended that any external condensate drain pipe is insulated and also must be of 40 mm 1 1 2 diameter through the outside wall to prevent freezing in adverse weather conditions The condensate is discharged periodically in slugs by siphonic action It is not necessary to provide air breaks or extra traps in discharge pipe as there is already a 125mm high trap inside the boiler Fitting an extra trap may cause the boiler siphon to work incorrectly Refer to 55546 or BS67968 for advice on disposal of boiler condensate Notes ALL EXTERNAL PIPE RUNS MUST BE IN ACCORDANCE WITH BS 6798 1 INTERNAL TO SINK WASTE UPSTREAM OF SINK WASTE TRAP Open end of pipe direct into gulley below grating but above water level Ground level 2 INTERNAL CONNECTION TO SOIL AN VENT STACK Make connection to SVP using a solvent welded saddle
164. rked Fit a roof flashing slate to the roof available from The White Boiler Company Insert the Vertical Flue terminal assembly through the flashing slate from the outside Lift the boiler on the wall locating onto the top two fixing bolts Tighten the two bolts using a spanner to secure to the wall Measure the vertical distance between the top of the flue and the bottom of the flue terminal assembly fig 21 The measurements should be taken from the outer diameter of the flue NOTE Where this length does not match any standard combination of the extensions only the extension can be cut to the required length fig 23 When cutting both inner and outer ducts of the extension always cut on spigot side and they must be de burred ACCESSORIES CONCENTRIC FLUE 60 100 EXTRAS TABLE 7 Part No Description Starting at the appliance end assemble the extension duct sections making each inner and outer flue joint by inserting the spigot end into the socket end of the next tube making sure the seal rings are correctly located fig 22 Make sure that the entire flue is adequately supported Use at least one bracket for each extension used Ensure that all inner flue connections have a good fit seal and that the space clips in each extension are correctly positioned 59 PR5094110A 60 100 PRFE PR45FBI PR9OFBI PR5023016 TER110200 45 bend 60 100 90 Elbow bend 6
165. rlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions What system cleaner was used What inhibitor was used Quantity Has a primary water system filter been installed CENTRAL HEATING MODE measure and record Gas rate OR Burner operating pressure if applicable OR Gas inlet pressure Central heating flow temperature Central heating return temperature COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm If yes and if required by the manufacturer has a water scale reducer been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas rate OR Burner operating pressure at maximum rate OR Gas inlet pressure at maximum rate Cold water inlet temperature Hot water has been checked at all outlets Yes Temperature Water flow rate CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 ALL INSTALLATIONS At max rate CO COz Record the following At min rate where possible The heating and hot water system complies with the appropriate Building Regulations The boiler and associated products have been installed and commissioned in a
166. rson s SELF CERTIFICATE SCHEME Choose BUILDING CONTROL Building Regulations notification route If you notify via Contact your relevant Gas Safe register They will Local Authority then notify the relevant Building Control LABC who Local Authority building will arrange an inspection Control LABC scheme or contact a government on members behalf approved inspector Gas Safe register engineers LABC will record the data log on to engineers section and will issue a of website at certificate of compliance www gassaferegister co uk or telephone 0800 408 5577 You must ensure that the IT IS A CONDITION OF THE notification number issued by MANUFACTURER S WARRANTY Gas Safe register is written THAT THE BENCHMARK onto the Benchmark Checklist COMMISSIONING CHECKLIST IS FULLY COMPLETED AND LEFT WITH THE APPLIANCE Gas Safe Register will record the data and will send a certificate of compliance to the property Benchmark Commissioning Servicing Section It is a requirement that the boiler is installed and commissioned to the manufacturers instructions and the data fields on the commissioning checklist completed in full To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation To maintain the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe registered engineer who has been trained on the boiler installed The servic
167. s CENTRAL HEATING MODE Measure and Record Gas Rate Burner Operating Pressure if applicable What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Burner Operating Cold Water Inlet Hot water has been checked at all outlets Water Flow Rate CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted ALL INSTALLATIONS If required by the manufacturer record the following co C OR CO 4 OR CO CO Ratio The heating and hot water system complies with the appropriate Building Regulations The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions The operation of the boiler and system controls have been demonstrated to and understood by the customer The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed Service Provider Before completing the appropriate Servic
168. s already been adjusted by the manufacturer during production If the adjustments need to be made again observe the following procedures The adjustment to fan speed must be strictly in the sequence indicated by qualified personnel only To check max fan speed see tables 11 A and 11 B Press P button item 8 fig 1 for 3 seconds to enter in menu Use arrow up and arrow down buttons item 3 and 4 fig 1 to select BOIL Press enter and reset buttons item 2 and 3 fig 1 together and enter button again Use arrow up and arrow down buttons item 3 and 4 fig 1 to select the followings options PM1 CH max fan speed PM2 DHW max fan speed Press enter item 1 fig 1 to select CH or DHW fan speed Adjust if necessary Fan Speed rpm TEST MODE It is possible to activate the test mode function by pressing the arrow up and the arrow down buttons item 3 and 4 fig 1 for 5 seconds Press the arrow up and the arrow down buttons to set the maximum or minimum fan speed The function is enabled for maximum 15 minutes and it has priority on D H W mode Press reset to esc test mode INSTRUCTING THE USER After completion of the installation and commissioning of the system the installer should hand over to the Householder by taking the following actions To the Householder explain His her responsibilities under the Gas Safety Regulations 2000 Explain and demonstrate the lighting and shutting down procedures
169. s disturbed when wiring external controls clearly marked on the packaging and To gain access to the electrical box remove boiler data badge the front panel of the case as described in clauses sect 8 2 To convert a boiler from one gas to You can slide towards the top the another this operation must be carried instrument panel box and push the retaining out by a qualified competent person latches and remove the instrument panel with all necessary equipment sect 8 24 authorised by the manufacturer Heat resistant flexible cable is fitted between the isolator and the terminal block which is 3 core cable of 0 75 24x0 2 to BS 6500 It will also be necessary to obtain a data badge me Company routed away from sharp edges and hot surfaces The cable must be fastened with its cord anchorage and connected so that should the cable slip from the anchorage the current carrying conductors become taut technical data before the earthing conductor Securely 4 Measure the level of CO2 as in section tighten all terminal screws and arrange 6 9 and table 10 and adjust to correct the cable with slack between the cord data settings information anchorage and the terminal block 5 Affix new data badge 6 Replace in reverse order WARNING If the supply cord is damaged it must be 5 28 ELECTRICAL CONNECTIONS replaced by a service engineer supply cord available from The White Boiler IMPORTANT Company Electricity supply must b
170. shing plate X plate N plate N plate N 600 Straight Flue Straight Flue Offset Flue Offset Flue 12 0 Max 12 0 10 m 11 plus Terminal plus Terminal plus 2 bend 90 plus 2 bend 45 and Terminal and Terminal Ensure that the maximum permissible flue length is not exceeded fig 20 and see table 5 fig 22 item 66 and ensure that the gasket Mark the two wall fixing bolt holes is correctly fitted Detach the template from the wall Use a 10 mm dia drill to make the 2 holes Important Make sure that the dia 60 mm Insert plastic expansion plug on the straight flue header is inserted Screw in the two coach bolts fully into the flue manifold and the flue Position the flue sample point starter straight manifold rubber seal is correctly fitted flue header which must be fitted and fix the Fig 22 item 65 securing screw on the flue adaptor appliance Cut 105 mm diameter hole through the ceiling and or roof at the point previously ma
171. shows an error Is 01E displayed No flame Check the gas supply Check the overheat thermostat Check the gas valve Check the spark igniter Check the electrodes Is icon 3 see fig 2 flashing Is 02 displayed Pump circulation failed Is 03E displayed C H flow sensor damaged Does the boiler go off Is 04 displayed D H W sensor damaged before set point Is displayed No PWM signal fan Is 06E displayed C H sensor overheating Check if the system has been purged of air Is 08E displayed Low water pressure system Is displayed Overheat sensor overheating Roomstat or time clock Is 10E displayed High water pressure system are satisfied Is 12E displayed Reset finished max 5 reset in 15 min Is 13E displayed Software error Is 21E displayed C H return sensor overheating Is 22E displayed Flue sensor overheating End of Central Heating test check Domestic Hot water 15 23E displayed Flue sensor damaged Is 24E displayed C H return sensor damaged Is 25E displayed Main heat exchanger frozen Is 26E displayed Control board damaged Is 29E displayed D H W sensor overheating Is 41E displayed Difference temp flow ret gt 35 for 25 sec Is 43E displayed Difference temp gt 40 C for 30 sec Is 44E displayed Difference temp gt 10 for 60 sec 9 1 FAULT FINDING DOMESTIC HOT WATER Before continuing see section 9 and after selecting the summer posi
172. ss importance of regular servicing by a qualified Heating Engineer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR Fill in the Benchmark log book and leave completed with the customer 6 14 RANGE RATING CENTRAL HEATING OR AND DOMESTIC HOT WATER 6 141 When the boiler operates in the C H mode the fan speed can be set between the min and max values See fig 37 This permits capacity to be adjusted to suit system demand if adjustment is required proceed as follows Remove front casing sect 8 1 4 Push the retaining latches and remove the front of the instrument panel Fig 54 Place instrument front panel into service holding bracket just above control box Fig 55 Place jumper on JP16 for test mode function Co Control is displayed on the digital display see sect 7 1 Using a small screw driver to adjust the potentiometer R9 CH max fan speed or and R19 DHW max fan speed clockwise to decrease the fan speed and anti clockwise to increase the fan speed Control board When viewing fan speed slightly move JE pc r3 the potentiometer to display the speed lo 7 G and adjust only if necessary fig 37 the po fan speed will flash the first two digits on the display in the control panel in rpm eg 42 4200 rpm JP2 Frequency meter connection E m
173. t or select the when the boiler is in winter mode section 1 4 group of days see table 2 then press the key 1 and also set in auto mode section 1 4 enter button key 7 If you wish to override these times press Press the up and down arrows to select the the timer mode button to select MAN this puts time first on time and press the enter the boiler in manual mode which overrides the button timer on the boiler so the heating is on Press the up and down arrows to set the permanently providing any external controls OF1 time first off and press enter fitted are calling for heat To turn the heating off Repeat this process for the remaining 3 press the timer mode button to select off this settings Note if not all 4 times are required will now turn the heating off permanently until then set the remaining on and off times to either auto or manual is selected 24 00 this cancels the remaining on and off For example see the weekend settings in Manufacturer s value table 1 On 2 Off 2 On 3 Off 3 Monday 11 00 13 00 17 00 23 00 Tuesday 11 00 13 00 17 00 23 00 Wednesday 6 11 00 13 00 17 00 23 00 TABLE 1 Thursday 6 11 00 13 00 17 00 23 00 Friday 11 00 13 00 17 00 23 00 Saturday 24 00 24 00 24 00 24 00 Sunday 24 00 24 00 24 00 24 00 Group MO SU Day 1 2 3 4 5 6 7
174. t is stopped by the timer or one of the thermostats When the internal C H temperature sensor intervenes the burner shuts down The fan stops but the pump continues to operate When the room thermostats intervene the burner shuts down The fan stops and the pump after 3 minutes turns off The boiler also incorporates an anti block system which powers the pump every 24 hours allowing it operate for 2 minutes if the boiler has not been in use This operation may in some cases be heard for a short period when the pump has been activated Domestic hot water mode The heat exchanger in the D H W circuit is a stainless steel plate heat exchanger water to water and domestic water is heated by converting the water in the central heating circuit The transference of heat is very high because the two fluids move in a counter direction Select summer winter switch Fig 33 switch pressed in the winter position Switch pressed in when a hot water tap is turned on the diverter valve motor moves to exclude the central heating circuit the boiler automatically modulates to maintain the domestic hot water at a constant temperature Water temperature can be regulated using the D H W thermostat located on the front control panel fig 33 When domestic hot water is being drawn the burner and pump perform as they do during central heating except that the burner is commanded by the D H W thermostat 8000 mm Max When D H W is no lo
175. t the system is flushed thoroughly before the appliance is fitted or left to operate as recommended in BS 7593 in order to maintain an efficiently operating heating system For replacement installations the system MUST be flushed with the old boiler in situ In order to prevent system debris Once the system has been flushed an inhibitor suitable for stainless steel heat exchanger should be added See section 4 8 11 Heating system A RETURN DRAIN TAP BY PASS Draining tap These must be located in accessible positions to permit the draining of the whole system The taps must be at least 15 mm nominal size and manufactured in accordance with BS 2870 1980 Air release points These must be fitted at all high points where air will naturally collect and must be sited to facilitate complete filling of the system The appliance has an integral sealed expansion vessel to accommodate the increase of water volume when the system is heated It can accept up to 7 Its of expansion water If the appliance is connected to a system with an unusually high water content calculate the total expansion see table 2 and add additional sealed expansion capacity as appropriate Fig 7 In general modern systems below 7 litre illing point Additional expansion vessel if required Mains water feed central heating There must be no direct connection to the mains w
176. t to exacting ISO 9001 discipline all boilers carry full CE marking of approval Technical sales and commercial services are available throughout the UK Mainland This product is guaranteed by The White Boiler Company Chartists Way Morley LEEDS LS27 9ET Telephone No 0113 252 7007 Guarantee is a full 12 months from date of purchase providing the appliance has been fitted in accordance with these instructions and relevant codes of practice MAJOR COMPONENTS Gas valve Variable head pump suitable for any type of central heating system Burner with flame stabiliser designed to operate under all thermal conditions Unique condensing heat exchanger for high thermal flue transfer from gases to water Stainless steel plate heat exchanger for super high heat transfer to domestic hot water supply Built in frost protection Printed circuit board designed to connect to room stat and or timer frost stat Aesthetically pleasing panels and controls On Off ball valves for shutting off gas central heating and domestic hot water circuit Safety relief valve for safety discharge Programmable 7 day module with digital display time clock version only NOTE Due to the high efficiency of this boiler a plume of water vapour will form at the flue terminal during operation COSHH CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH IMPORTANT It is the Users Installers responsibility to ensure that the necessary personal protective clothing is worn when
177. taining clip 8 10 3 Replace in reverse order Diverter valve switch Retaining clip V Fig 50 Unscrew the two allen screws and lift upthe plate heat exchanger Unscrew the two allen screws TO REMOVE REPLACE PUMP Fig 51 Remove front casing sect 8 1 4 Remove the bottom panel and the right side panel Drop down control box sec 8 20 Detach the supply wire connector from the pump Remove the securing clip at the pump manifold Fig 51 Remove the securing clip that fastens the pressure gauge to the pump Fig 51 Unscrew the nut that fastens the pump to the CH pipe and remove the pump Replace in reverse order NOTE Alway use new seal and new O ring when re fitting new pump REMOVE REPLACE AUTOMATIC TO REMOVE REPLACE C H AIR VENT Fig 51 DIVERTER VALVE Remove front casing sect 8 1 4 Remove the bottom panel and the right Remove front casing sect 8 1 4 side panel Remove the bottom panel and the right side panek Close the on off valves for C H circuit and drain the water from at drain point Fig 35 Drop down control box sec 8 20 Remove the pump see sect 8 11 Close the on off valves for the heating circuit and drain the water at drain point Remove the retaining clip holding the Fig 35 automatic air vent Remove diverter valve motor to allow Pull the automatic air vent from the pump access sect 8 10 Replace in reverse order and check for
178. tal flue outlet is not possible or desired L The vertical flue can be used either with a flat roof or a pitched roof maximum pitch 60 Where a straight vertical flue is not possible or desired an offset vertical flue can be used in conjunction with a side horizontal flue extension piece and in line 1357 90 flue bend fig 19 AN IMPORTANT NOTES For greater flue length see twin flue or concentric 80 125 flue instructions Proceed with installation as detailed in section 5 ignoring all references to horizontal flue installations To overcome Use adhesive tape to attach the template to the wall low roof or making sure that the centre line is vertical and that the below ground basement flue centre line is virtually below the point at which the installations flue will exit the roof Fig 19 F Tor m Vertical standard Vertical standard Vertical standard Vertical standard flue kit 1100mm k flue kit 1100mm flue kit 1100mm flue kit 1100mm Must NOT be shortened Must NOT be shortened Must NOT be shortened Must NOT be shortened Collar Flashing Flashing Flashing Fla
179. tallers are required to carry out work in accordance with the following THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS The use of the word installer is not limited to installation itself and covers those carrying out installation commissioning and or servicing of heating and hot water products or the use of supporting products such as water treatment or test equipment Customer includes householders landlords and tenants Heating and Hotwater Industry Council HHIC Standards of Work Be competent and qualified to undertake the work required Install commission service and use products in accordance with the manufacturer s instructions provided Ensure that where there is responsibility for design work the installation is correctly sized and fit for purpose Meet the requirements of the appropriate Building Regulations Where this involves notifiable work be a member of a Competent Persons Scheme or confirm that the customer has notified Local Authority Building Control prior to work commencing Complete all relevant sections of the Benchmark Checklist Service Record when carrying out commissioning or servicing of a product or system Ensure that the product or system is left in a safe condition and whenever possible in good working order Highlight to the customer any remedial or improvement work identified during the course o
180. te Where Possible At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 03 SERVICE 04 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 05 SERVICE 06 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 07 SERVICE 08 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 09 Signature SERVICE 10 Engineer name Engineer name Company name Company name Telephone No Telephone No
181. ted when Domestic Hot Water is being drawn off domestic hot water has priority This will normally not affect the level of Heating PLEASE NOTE Due to the high efficiency of this appliance and resulting low flue gas exhaust temperature a white plume of condensation vapour cool steam will be emitted from the flue outlet terminal this is quite normal It will be particularly evident during periods of low outdoor temperature or when the boiler is working at its optimum performance Plume Management kits are available on request IMPORTANT In the unlikely event of the exhaust flue gases exceeding the overheat temperature setting the boiler operation will be stopped to prevent damage to the appliance CLEARANCES AROUND THE APPLIANCE Side clearance The position of the appliance must provide a minimum clearance of only 5mm as the side panels do not require removing for servicing However if the option is preferred to remove the panels then a minimum clearance of 55mm is required Top clearance The top clearance should be a minimum of 125 mm Bottom clearance A minimum bottom clearance of 80 mm is required between the appliance and any surface though 150 mm is preferred whenever possible Front clearance A minimum of 450 mm is required in front of the appliance for access during servicing the front clearance can be reduced when installed in a cupboard to 25 mm from the access door USER CONTROLS This app
182. the boiler inlet gas connection should not be used The complete installation must be tested for soundness as described in the above code N B It is the responsibility of the Gas Installer to size the gas installation pipework in accordance with BS 6891 2005 Whilst the principle of the 1 1 gas valve ensures the White Heat range is able to deliver the full output at an inlet pressures as low as 14 mbar other gas appliances in the property may not be as tolerant When operating pressures are found to be below the minimum meter outlet of 19 mbar these should be checked to ensure this is adequate for correct and safe operation pressure drop mbar 4 7 Allowing for the acceptable pressure loss of 1 mbar across the installation pipework it can be assumed that a minimum permitted operating pressure of 18 mbar will be delivered to the inlet of the appliance reference BS 6400 1 Clause 6 2 Pressure Absorption The external gas cock could further reduce the operating pressure when measured at its test point The pressure drop is relative to the heat input to the boiler kW refer to graph below Gas cock pressure drop 15 0 20 0 25 0 heat input boiler kW FLUE SYSTEM The terminal should be located where dispersal of combustion products is not impeded and with due regard for the damage or discolouration that might occur to building products in the vicinity section 4
183. tion on the digital display and setting the domestic hot water temperature to maximum sect 1 5 Open the domestic hot tap and check the following appliance operations Ensure domestic hot water flow is min of 3 l min yes Check filters are clean Is icon 12 see fig 2 flashing yes Check replace the domestic hot water flow detector magnet Does the display shows an error no See list in section 9 0 Does the boiler go off before set point no Check replace the domestic hot water sensor and check the plate heat exchanger is clear of any debris End of Domestic Hot Water test ELECTRICAL SYSTEM DIAGRAM Flame input Sparking f igniter Earth power 6666666 1 Line power Neutral Sparking igniter Room thermostat Volt free or o NO H d or N Neutral Overheat thermostat 97 3 DHW probe r s Pump yg CH Flow NTC probe 24 VDC bk signal B Hall effect x5 br GND Z j br 75 Return NTC probe O 5 4 Colour code bk black bl blue br brown green orange red violet w white yellow yg yellow green
184. to 1 5 bar Max Main Switch on Select Winter Central Heating control knob to maximum Ensure external controls calling for heat Room stat Timeclock TRV Does heating LCD Is 230 at L N Check Replace on digital display connections on ____ external Fuse and illuminate control board supply Yes Yes Replace On Off Switch 2 Is low pressure Yes __ Check Replace Does the pump run in the system 15 230V at pump pump if necessary Re pressure the Is there continuity at Replace system summer winter switch summer winter switch Check Replace Timeclock if OK Replace control board FAN SEQUENCE CODE Is the burner led Check Fan Voltage illuminate on Is 17 displayed Check fan control panel No IGNITION SEQUENCE CODE Check condensate drain if is not blocked Is 01 displayed Check gas valve operation Check the fan starts Check Ignition control board and cables No Overheat thermostat not connected Is 28 displayed LOW WATER DIFFERENTIAL PRESSURE SWITCH OR PUMP SEQUENCE CODE No Check Replace Low water pressure switch Check pump Check system pressure Is 12 displayed Yes HEATING SENSOR SEQUENCE CODE Check Replace heating sensor Check circulation Is 04 displayed OVERHEAT SEQUENCE CODE o Check the overheat thermostat Is 30 displayed AS FLUE TEMPERATURE SEQUENCE CODE Check operating system No FLUE TEMPERATURE SEQUENCE CODE Is 31 displayed Yes
185. tom of the casing Make sure the casing and screws are put to one side in a safe place OPTIONAL EXTRAS See Table 4 20 HORIZONTAL FLUE KIT BOX CONTAINING Fig 10 59 Rubber seal 60 56 Rubber seal 100 60 Fumes sample point 61 Flue exhaust duct 62 Air intake duct 69 Air sample point 127 Terminal Rubber wall seal 128 Elbow header IMPORTANT Please lubricate the internal part of the seals before being fitted Generally speaking oils and greases are not suitable for the peroxide EPDM therefore we suggest a correct lubrication using silicon substances for instance Silikon Spray Arexons or the same product from the company Soltecno s r l FLUE EXTENSION BOX CONTAINING Fig 11 1000 mm flue extension duct as an extra cost only when requested for side and vertical flue applications 59 Rubber seal 60 63 Air intake duct extension 64 Flue exhaust duct extension 64 TYPE OF FLUE SYSTEM minimum and maximum distance WARNING with horizontal concentric flue Maximum allowable flue length 8 m maximum flue duct extension used with standard flue see table 3 TABLE 3 Flue Diameter uu 00 80 125 60 100 80 125 80mm concentric concentric concentric concentric single pipe 1 0 1 0 vertical length vertical length 13 0 26 0 Minimum length Maximum length m Equivalent length of 45 ben
186. trol box fig 53 4 f Lj over to the left while still pulling This will allow free access to lower part it forward until the box becomes free of the boiler Bs Control box A AS NY D Service retaining clip NZD a T i Lift and hook with service retaining clips Service retaining clip EXTERNAL CONTROL CONNECTION Fig 54 TO REMOVE THE INSTRUMENT PANEL Fig 54 Remove front panel fig 39 Remove the external wire link on the Remove front panel fig 39 panel control box Push the four retaining latches and Replace with external wire controls remove the front of the panel box fig These must be volt free 54 Instrument panel Control box TO REMOVE REPLACE CONTROL BOARD Fig 55 Push the retaining latches and pull the instrument panel
187. trols For replacement of parts the front side and bottom panel panels of the boiler will need to be removed To remove the front panel unscrew the two cover screws that secure the front panel to the boiler and lift off To remove the bottom panel unscrew the four screws and lift off To remove the side panels remove the front and bottom panels unscrew the screw s below and remove Fig 40 TO REMOVE REPLACE SPARK IGNITER BOX Fig 41 Remove the front casing sect 8 1 4 Detach all the connectors from the igniter control box Remove the 2 screws that secure the spark igniter to the bracket Replace in reverse order Spark igniter box Yo D Retaining nuts 250V connector to detach Push and pull to detach PVM connector TO REMOVE REPLACE THE ELECTRODES Fig 36 Remove the front casing panel sect 8 1 4 Remove the ignition and or sensing lead plug Unscrew the two securing screws and put them into a container so that they don t get lost Withdraw the Spark electrode and or sensing electrode carefully from the combustion chamber cover being careful not to damage the seal Replace with new electrode in reverse order Ensure gap is correct and there is a good seal when repla
188. ty Regulations NOTE Check and record CO level and combustion ratio at both maximum AND minimum rate before contacting Ravenheat Oz more than or equal to 20 6 or COz less than or equal to 0 2 When checking the O the front cover must be on so the air is drawn from outside Check CO level and Combustion ratio at Maximum Gas Rate With boiler still set at maximum gas rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording Is CO level less than 350 ppm AND CO CO ratio less than 0 0040 ensure this check is done with the cover off and with the cover on to check the integrity of the flue Set Boiler to maximum Gas Rate In accordance with boiler instructions set boiler to operate at manimum rate to minimum load condition Allow sufficient time for combustion to stabilise Check CO and Combustion ratio at Minimum Gas Rate With boiler set at minimum rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording Is CO level less than 350 ppm AND CO COz ratio less than 0 0040 Boiler is Operating Satisfactorily No further actions required Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed Complete benchmark Checklist recording CO and combustion ratio readings as required THE WHITE BOILER COMPANY GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commiss
189. ue exhaust manifold WH 80 main heat exchanger Expansion vessel 3 8 gasket GUA060111 Expansion vessel pipe 1 4 gasket Flow pipe 1 gasket GUA010311 571 _ SCA150100 WH 90 main heat exchanger Plume Management Kit see sect 5 6 Part No Description TER110101 1 metre high plume kit CUR110050 45 flue exhaust deflection bend CUR11010 90 flue exhaust deflection bend Accessories concentric flue 60 100 see sect 5 12 Table 7 Part No Description Accessories concentric flue 80 125 see sect 5 18 o Accessories eccentric flue 80 80 see sect 5 13 5 14 5 15 5 16 5 17 MEER THE WHITE BOILER COMPANY A Ravenheat Group Company Chartists Way Morley Leeds LS27 9ET Telephone 0113 252 7007 Fax 0113 238 0229 Website www ravenheat co uk E mail sales ravenheat co uk Ravenheat reserves the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet COD 0017LIB15005 0 07 2014 12 BENCHMARK COMMISSIONING CHECKLIST DETAILS Boiler Page Make and model Appliance serial no on data badge Controls Temperature control to Temperature control to hot Heating zone valves Auto by pass Boiler interlock For all boilers Flushing to BS7593 Inhibitor Central heating mode H
190. ush so as to locate inner and outer flue correctly ensuring a good seal is made with O rings Tighten the two screws on the flue flange to secure the elbow header in place Fit the terminal rubber wall seal and if necessary terminal guard Extension kits are available to order for flue extension of up to a total overall length of 8 metres fig 18 Each extension length extends the pipe by approximately 1000 mm long up to a maximum of seven extensions Extensions must be installed with the widened end of the air intake pipe and the tapered end of the flue pipe aimed towards the exhaust terminal IMPORTANT Inline flue bend 1000 mm must be deducted f rom overall length for each 90 bend Obtuse flue bend 500 mm must be deducted from overall length for each 135 bend see table 5 INSTALLING THE APPLIANCE FOR SIDE FLUE OUTLET Fig 14 15 16 17 18 Attach the template to the wall with adhesive tape making sure that the centre line is vertical and that the distance from the centre line to the nearest side wall is not less than measurement in fig 14 Mark the two fixing bolt securing holes on the wall and extend the axis of the flue duct hole to the side wall ensuring it is horizontal Make sure flue slopes 1 5 down towards the boiler and that there is a 25 mm fall per metre of the flue length Trace the centre of the flue duct hole and measure distance from the corner of the wall fig 14 measure the dist
191. ustomer Rectify any installation problems at no cost to the customer during the installer s guarantee period www centralheating co uk INSTALLER NOTIFICATION GUIDELINES Achange to Building Regulations England and Wales requires the installer to notify when installing a heating appliance as from 1st April 2005 Install and commission this appliance to manufacturers instructions Complete the Benchmark Checklist Competent Person s Choose SELF CERTIFICATION SCHEME BUILDING CONTROL Buildings Regulations notification route Contact your relevant If you notify via Local Authority Gas Safe Register they will T then notify the relevant Building Control LABC who Local Authority Building will arrange an inspection Control LABC scheme or contact a government on members behalf approved inspector LABC will record the data Gas Safe Register Engineers and will issue a log on to the engineers section certificate of compliance of the website at www gassaferegister co uk or telephone 0800 408 5577 You must ensure that the notification number issued by Gas Safe Register is written IT IS A CONDITION OF THE onto the Benchmark Checklist MANUFACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS Gas Safe Register will record the data and will send a certificate FULLY COMPLETED AND LEFT of compliance to the property WITH THE APPLIANCE This Commissioning Checklist is to be completed in full by t
192. uture use Press the P button once to return to the main screen In the event of an error the appliance will show a sequence code displayed on the digital display of the control panel fig 1 By pressing the RESET button it is possible to relight the boiler see page 51 for list of error codes 1 4 APPLIANCE STATUS INDICATORS Your boiler is equipped with a large LCD display During the initial charge time the display doesn t that indicates the appliance operating status allow the visualisation and or modification function fig 1 parameters Instead other functions are working When the appliance operates in rest mode the After a long period switched off no power display shows the boiler temperature and for the supply the first switch on the internal backup time clock version only the time Alternatively the circuit will charge in order to maintain time digital display also shows the water pressure and update parameters The screen will display CLOW after a few minutes of power supply the display will be charged enough to allow all the functions KEY 1 ON OFF button 7 TIMER MODE time clock version only Press to turn the boiler ON SUM hot water Press to select Auto heating times set Manual only WIN hot water and heating if set and heating on all the time and off heating off OFF Press the button also to confirm selections
193. ve S O 29 Piate neat exchanger Oring 30 SCA110350 Plate heat exchanger 31 GRU10050 Flowmanifold S s Sseyrletvave ss __ Dwetervavemotrswih Ci __ CH dweervave 7 1 ie 6 LM 9 ELEM i5 TRAI3000 16 Erg G C Description Part No ss Rivno DHWsewr oo a water pressure switch as PREnoro Diferential pressure switch oRuno Plume Management Kit page 20 Part No Desripion o O TER110101 1 metre high plume kit CUR110050 45 flue exhaust deflection bend CUR11010 90 flue exhaust deflection bend Accesories concentric flue 60 100 page 25 Table 4 PR5094110A PRFE PRASFBI PROOFBI PR5023016 PR5023016 TER110200 Vertical flue Terminal Accesories concentric flue 80 125 page 28 Description PR5094110A Straight flue header sample point 60 10 PRO110300 Flue Extension 80 125 L1000 RID110050 125 80 to 100 60 Flue reducer CUR110300 TERO10050 TER110200 0060050 CUR110250 45 bend 80 125 Accesories eccentric flue 80 80 page 26 500110050 PROTIO200 008110150 009110250 6810050 6810100 TERO60110 THE WHITE BOILER COMPANY a Ravenheat Group Company Chartists Way Morley Leeds LS27 9ET Telephone 0044 0 113 252 7007 Tfax 0044 0 113 238 0229
194. witch or appliance control utilising mains electricity should be situated so that it cannot be touched by a person using a bath or shower A compartment when used to enclose the combination boiler MUST be designed and constructed specifically for this purpose An existing cupboard or compartment may be used provided it is modified accordingly Samples of the WH 80 90 T combi boiler have been examined by CERTIGAZ notification body and are certified to comply with the essential requirements of the gas appliance Directive 90 396 EEC the Low Voltage Directive 72 23 EEC and shows compliance with the Electro Magnetic Compatibility Directive 89 336 EEC and are therefore permitted to carry the CE Mark The appliance has been tested and approved by the WRc as meeting the requirements of G3 and L of the Building regulations and water Bylaws Scheme Approved Products GAS SUPPLY A gas meter is connected to the service pipe by the Local Gas Region or the Local Gas Region contractor An existing meter should be checked preferably by the Gas Region to ensure that the meter is adequate to deal with the rate of gas supply required for all appliances it serves Installation pipes should be fitted in accordance with BS 6891 2005 Pipework from the meter to the boiler must be of adequate size 22 mm min to within at least one metre of the boiler 15 mm min can then be used for remaining pipe work to the appliance A smaller size than
195. xceed the min 2 38 gals min 650 It h when the burner is firing It is important to ensure that this rate is achieved when sections of the system are shut off either manually or by automatic controls If the volume of circulating water is too low the boiler water temperature will rise too rapidly This could cause noise in the system or even cause the safety thermostat to trip This appliance is designed to work on a two pipe system as shown in fig 6 BOILER INTERLOCK CONTROL Central heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating in compliance with Building Regulations The boiler has its own built in bypass If the system has thermostatic radiator valves on all radiators or two port valves then a bypass circuit must be fitted with an automatic bypass valve to ensure a flow of water should all valves be in the closed position fig 6 It is important that the system is flushed thoroughly before the appliance is fitted or left to operate as recommended in BS 7593 in order to maintain an efficiently operating heating system For replacement installations the system MUST be flushed with the old boiler in situ in order to prevent system debris Once the system has been flushed an inhibitor suitable for stainless steel and aluminium heat exchanger should be added see section 4 18 DRAINING TAP These must be located in accessible positions to perm

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