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Table of Contents
1.0
INTRODUCTION ....................................................................................................................................................................................................................................................................... 5
2.0
SAFETY GUIDELINES ............................................................................................................................................................................................................................................................. 6
2.1
GENERAL DESCRIPTION OF SAFETY SYMBOLS USED .................................................................................................................................................................................................................. 6
2.2
WHAT TO DO IF YOU SMELL GAS ...................................................................................................................................................................................................................................................... 7
3.0
PRINCIPLE PARTS .................................................................................................................................................................................................................................................................. 8
4.0
TECHNICAL DATA ................................................................................................................................................................................................................................................................ 10
5.0
DIMENSIONS AND CLEARANCE ........................................................................................................................................................................................................................................ 11
5.1
DIMENSIONS ........................................................................................................................................................................................................................................................................................ 11
5.2
CLEARANCES ...................................................................................................................................................................................................................................................................................... 12
6.0
GENERAL REQUIREMENTS ................................................................................................................................................................................................................................................ 13
6.1
RELATED DOCUMENTS ..................................................................................................................................................................................................................................................................... 13
7.0
WATER QUALITY .................................................................................................................................................................................................................................................................. 14
8.0
LOCATION .............................................................................................................................................................................................................................................................................. 14
8.1
PLANT ROOM REQUIREMENTS ........................................................................................................................................................................................................................................................ 14
8.2
GENERAL REQUIREMENTS ............................................................................................................................................................................................................................................................... 14
8.3
CONDENSATE DRAIN ......................................................................................................................................................................................................................................................................... 14
9.0
GAS SUPPLY ......................................................................................................................................................................................................................................................................... 15
9.1
SERVICE PIPES ................................................................................................................................................................................................................................................................................... 15
9.2
METERS ................................................................................................................................................................................................................................................................................................ 15
9.3
GAS SUPPLY PIPES ............................................................................................................................................................................................................................................................................ 15
9.4
BOOSTED SUPPLIES .......................................................................................................................................................................................................................................................................... 15
9.5
PLANT-ROOM CONTROL VALVE ....................................................................................................................................................................................................................................................... 15
9.6
EQUIPMENT GAS SYSTEM LEAK CHECK ........................................................................................................................................................................................................................................ 15
10.0
FLUE SYSTEM ....................................................................................................................................................................................................................................................................... 16
10.1
FLUE SYSTEM GENERAL REQUIREMENTS .................................................................................................................................................................................................................................... 16
10.2
FLUE DISCHARGE ............................................................................................................................................................................................................................................................................... 18
10.3
CONDENSATE DRAIN ......................................................................................................................................................................................................................................................................... 18
10.4
FLUE SYSTEM GENERAL REQUIREMENTS .................................................................................................................................................................................................................................... 19
10.5
APPROVED FLUE SYSTEM ................................................................................................................................................................................................................................................................ 19
10.6
INSTALLATION PRECAUTIONS ......................................................................................................................................................................................................................................................... 19
10.7
CONDENSATE DRAIN ......................................................................................................................................................................................................................................................................... 19
10.8
CONVENTIONAL FANNED FLUE ....................................................................................................................................................................................................................................... 19
23
10.9
ROOM SEALED (TYPE C) FLUE ASSEMBLY .................................................................................................................................................................................................................................... 20
10.10
C13 CONCENTRIC HORIZONTAL FLUE SYSTEMS ................................................................................................................................................................................................................. 22
10.11
HORIZONTAL FLUE TERMINAL INSTALLATION ...................................................................................................................................................................................................................... 23
10.12
FLUE TERMINAL GUARDING ...................................................................................................................................................................................................................................................... 23
10.13
C33 CONCENTRIC VERTICAL FLUE SYSTEMS ....................................................................................................................................................................................................................... 24
10.14
VERTICAL FLUE TERMINAL INSTALLATION ............................................................................................................................................................................................................................ 24
10.15
COMMON VENTED FLUE SYSTEMS IN MULTI FLOOR BUILDINGS ................................................................................................................................................................................ 30
43
10.16
(TWIN PIPE) FLUE SYSTEMS ............................................................................................................................................................................................................................................... 31
53
10.17
FLUE TERMINAL GUARDING ...................................................................................................................................................................................................................................................... 35
10.18
(CONVENTIONAL FLUE WITH FAN ASSISTANCE) .................................................................................................................................................................................................. 36
23
10.19
CERTIFIED FLUE SYSTEMS ................................................................................................................................................................................................................................................. 37
63
11.0
AIR SUPPLY ........................................................................................................................................................................................................................................................................... 38
11.1
COMBUSTION VENTILATION ............................................................................................................................................................................................................................................................. 38
11.2
COOLING VENTILATION ..................................................................................................................................................................................................................................................................... 38
12.0
WATER CONNECTIONS ....................................................................................................................................................................................................................................................... 39
12.1
GENERAL.............................................................................................................................................................................................................................................................................................. 39
12.2
OPEN VENTED SYSTEM ARRANGEMENT ....................................................................................................................................................................................................................................... 39
12.3
UNVENTED SYSTEM ARRANGEMENT ............................................................................................................................................................................................................................................. 40
13.0
ELECTRICAL SUPPLY .......................................................................................................................................................................................................................................................... 42
13.2
EXTERNAL CONTROLS ...................................................................................................................................................................................................................................................................... 43
13.3
MAINS POWER SUPPLY ..................................................................................................................................................................................................................................................................... 43
13.4
LOW VOLTAGE CONNECTOR STRIP ................................................................................................................................................................................................................................................ 44
13.5
ELECTRICAL CONNECTIONS ............................................................................................................................................................................................................................................................ 45
13.6
FUSES ................................................................................................................................................................................................................................................................................................... 45
13.7
ARC WELDING PRECAUTIONS .......................................................................................................................................................................................................................................................... 45
13.8
WIRING DIAGRAM ............................................................................................................................................................................................................................................................................... 46
13.9
LADDER DIAGRAM .............................................................................................................................................................................................................................................................................. 47
14.0
USER CONTROL INTERFACE ............................................................................................................................................................................................................................................. 48
14.1
GENERAL.............................................................................................................................................................................................................................................................................................. 48
14.2
USER CONTROL INTERFACE PANEL ............................................................................................................................................................................................................................................... 48
14.3
SEQUENCE OF OPERATION .............................................................................................................................................................................................................................................................. 49
15.0
COMMISSIONING AND TESTING ........................................................................................................................................................................................................................................ 51
15.1
ELECTRICAL INSTALLATION ............................................................................................................................................................................................................................................................. 51
15.2
GAS INSTALLATION ............................................................................................................................................................................................................................................................................ 51
15.3
WATER CONNECTIONS ...................................................................................................................................................................................................................................................................... 51
15.4
COMMISSIONING THE EQUIPMENT ................................................................................................................................................................................................................................................. 51
15.5
TEMPERATURE ADJUSTMENT PROCEDURE ................................................................................................................................................................................................................................. 52
15.6
INSTALLATION NOISE......................................................................................................................................................................................................................................................................... 52
16.0
LPG FUEL ............................................................................................................................................................................................................................................................................... 53
16.1
RELATED DOCUMENTS ..................................................................................................................................................................................................................................................................... 53
16.2
CONVERSION TO LPG ........................................................................................................................................................................................................................................................................ 53
16.3
LPG COMMISSIONING AND TESTING .............................................................................................................................................................................................................................................. 56
17.0
MAINTENANCE ...................................................................................................................................................................................................................................................................... 57
17.1
GENERAL.............................................................................................................................................................................................................................................................................................. 57
17.2
BURNER INSPECTION ........................................................................................................................................................................................................................................................................ 57
17.3
BURNER REMOVAL ............................................................................................................................................................................................................................................................................. 57
17.4
CLEANING THE HEAT EXCHANGER ................................................................................................................................................................................................................................................. 58
17.5
DRAINING THE WATER HEATER SYSTEM ...................................................................................................................................................................................................................................... 58
17.6
STORAGE VESSEL: INSPECTION AND CLEANING ......................................................................................................................................................................................................................... 58
17.7
SACRIFICIAL ANODES: INSPECTION AND REPLACEMENT .......................................................................................................................................................................................................... 59
17.8
REFILLING THE SYSTEM .................................................................................................................................................................................................................................................................... 59
3
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