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BOILEr INSTALLATION
5.0
5.1 uNPAcKING OF BOILEr
Important Note: With regard to the Manual Handling Operations, the following
lift operation exceeds the recommended weight for a one man lift.
Place the boiler carton horizontal as indicated on the packaging labels. Cut
and remove the securing straps and lift off the carton sleeve. Place aside any
loose components until required.
Remove the two securing screws at the bottom of the front panel and carefully
lift off the front panel from the two retaining lugs at the top. Place the front
panel in a safe place.
Undo the water and gas connections (these are hand tight only) between the
back plate manifold and the boiler connections. Place aside safely the connector
washers as these will be required later. Carefully lift the boiler from the back
fixing plate by first sliding it towards the top to disengage it from the fixing
brackets. Place the boiler on its back in a safe place.
5.2 BOILEr FIXING
a)
Wall Template
A wall template is supplied with the boiler. This should be used to mark the
boiler fixings and the flue outlet and for checking the minimum clearances
required. Check the flue outlet/pipe run/terminal position does not clash with
any structural members before finalising the boiler position.
b)
Flue hole cutting
The standard horizontal flue is designed with an internal fall of 30mm/metre
towards the boiler for disposal of condensate. If the standard flue length alone
is being used then a flue hole of diameter 105mm can be cut in the position
marked on the wall template.
For standard side flues the horizontal flue centre line on the wall template
should be extended to the side wall, and the vertical centre of the flue hole
marked at 180mm from the back wall.
For installations with external access, a 105mm diameter core drill can be
used and for installations with internal access only, a 15mm diameter core
drill should be used.
When using extension pipes with the horizontal rear flue, a core drill size of
15mm should be used to allow the extension pieces through the wall to slope
at 18mm/metre (1½°) towards the boiler. If necessary remove the wall template
whilst drilling the flue hole.
For extended side flues, the flue hole centre should be determined by extending
the dashed inclined line on the template to the side wall. This dashed line is
drawn at 18mm/metre (1½°) rise from the boiler. Where this line reaches the
side wall, a horizontal line should be marked. The vertical centre line of the flue
should then be marked at 180mm from the back wall (see figure 4.1).
To allow for the flue passing through the wall at this angle a 15mm hole should
be drilled irrespective of internal or external installation.
c)
Hanging the back plate
If previously removed, reposition the wall template and mark the position of
the fixing holes for the back plate.
Mark and drill the fixing holes and secure the back plate to the wall ensuring
that the boiler brackets on the back plates are level in the horizontal plane.
d)
Boiler fixing
Important Note: With regard to the Manual Handling
Operations, the following lift operation exceeds the
recommended weight for a one man lift.
Having previously secured the back plate assembly to
the wall, lift the boiler into position in the following
manner: -
Lean the top of the boiler slightly to the wall and with
the sides inline with the back plate assembly lift the
boiler about 50mm above the back plate assembly on
the wall. Allow the boiler to slowly move downward
and towards the backplate until it is engaged
simultaneously in both the top and bottom brackets
on the back plate assembly.
Insert the washers between the valves on the back
plate manifold assembly and the boiler connections.
Tighten all the connections.
5.3 cONNEcTIONS
a)
Heating/DHW pipe connections
The central heating, cold water, domestic hot water and
gas pipes can be connected to the appropriate copper
tails as shown in figure .7 (Page 11).
Note: The pipe connections can also be made before
the boiler is fixed to the back plate assembly.
b)
Pressure relief valve discharge
Run the discharge from the pressure relief valve outlet
in 15mm copper (minimum) to outside the building.
See section 4. (g) for further details.
c)
condensate drain connection
Connect the condensate drain to the trap outlet pipe
(see figure 4.9) located in the hydro-block chamber of
the boiler. Undo the screw securing the wiring panel
to the boiler and swing it open to gain access to the
condensate drain connection.
The connection will accept 1 or mm O.D. plastic pipe
which should discharge internally into the household
drainage system. If this is not possible, discharge into
an outside drain is acceptable. (See section 4.(e) for
further details.
Page 4
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