Page 1: ...EGULATIONS It is the law that all gas appliances are installed by a competant person in accordance with the above regulations For use on natural gas only G20 G C No 47 980 04 from serial number Installation and Senrkhg Instructions leave these instructions with the user Looking Good Heatfng Better ...
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Page 3: ...tionalFlow Wiring DiagramFig 8 IllustratedWiring DiagramFig 9 2 INSTALLATION REQUIREMENTS 2 1 General 2 2 Location 2 3 WaterCirculationSystem 2 4 Siting theFlueTerminalFig 10 2 5 Air Supply 2 6 Electrical Supply 2 7 GasSupply 3 SYSTEM GUIDANCE 3 1 General 3 2 SystemControls 3 3 PumpFig 11 3 4 ExpansionVessel 3 5 MainsWaterConnection 3 6 Filling andRechargingFig 12 Fig 13 page12 3 7 MakeupSystem 3 ...
Page 4: ...NG 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 6 10 6 11 Hot WaterCircuits Filling Fig 33 CentralHeatingCircuits Filling Fig 34 G Lighting theBoiler Fig 35 GasRateAdjustmentFig 36 37 Fig 38 DomesticHot Water Flow RateAdjustment seealso6 7 Fig 393 Adjusting theHeatingSystemBy PassFig 39 DomesticHot Water flow RateAdjustmentFig 39a PumpSwitchingAdjustmentFig 39b CentralHeatingTemperature Differential Settin...
Page 5: ...oard Fig 64 Electricalbox layoutFig 65 8 19 To ReplaceSolenoidsValvesFig 66 8 20 To ReplaceHeatingBodyLiningsFig 67 8 21 To ReplaceFanAssemblyFig 68 8 22 To ReplacePressure Switch HorizontalFlue Fig 69 8 23 To ReplacePressure Switch VerticalFlue Fig 69a 8 24 To Re pressurise ExpansionVesselFig 70 8 25 To ReplacePressure GaugeFig 71 8 26 To ReplacetheDomesticExpansionVesselFig 72 8 27 To ReplaceMai...
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Page 7: ...mbustion Chamber Lining platerial Alumino Silicone Fibre Precautionq During servicing keep the dust generation to a minimum and avoid inhaling any dust and contact with the skin and eyes Normal handling and use will not present any discomfort although some people with a history of skin complaints may be susceptible to irritation When disposing of the lining ensure that it is securely wrapped and w...
Page 8: ...d to the rear or to the lef or right and can be extented to a maximum length of 3 m or 1 6 metres horizontally using the available 90 bend see sections 1 4 1 1 4 2 and 1 4 3 figures 2 3 3a 3b 3 2 Vertical flue option see section 1 4 4 Guarantee Fully adjustable central heating flow temperature regulation between 40 C and 82 C High limit thermostat for both boiler and hot water Water flow switch to...
Page 9: ...obe SAPCO Thermistor SIEMENS Boiler fiiit thermostat SOPAC JAEGER 85X Hot water limit thermostat SOPAC JAEGER 57 C 3 C Safety overheat thermostat TOKOSWHCH 105 C manual reset ELMWOOD Overheat high Iiit thermostat TOKOSWITCH 1lO C automatic reset ELMWOOD 105 C Gas valve AEMF Fan motor SEL Manifold injectors 14 of 1 28 mm 0 05 in Gas section restrictors 213 valves 4 4 mm 0 17 in I Pump head GRUNDFOS...
Page 10: ...ed length L Cut off surplus i om plastic air duct plain end N B If extension sections are used ensure these are filly pushed together see figs 3b and 3c and a fall of 5 Cut off same amount from Fig 3 SIDE OUTLET ASSEMBLY Fig 3a PLASTIC AIR DUCT Other Flue Arrangements Hotizontal 1 Distance from internal comer 300 mm without kit 107 mm with kit No 76216 GC No 264 833 2 Distance below balconies or e...
Page 11: ...th four 45 bends fig 3 f and 3 g 1 Adaptor 2 Extensions 6 m maximum tig 3 f and 3 g including horizontal 2 m maximum fig 3 f 3 Roof tlashiig 4 Terminal 5 45 bends x 4 maximum fig 3 f and 3 g 6 Reducer With the exception of 3 roof fIashing and 4 terminal all other fittings are designed for interd installation only N B In these two arrangements tigs 3 f and 3 g the total length of straight extension...
Page 12: ...heat exchanger fO EIectriciaI box containing Mains connection Fuses Printed circuit boards Connections for external controls Connections for fan pressure switch and flow switch Connections for pump Connections for change over valve and for gas solenoid valve Indicator LEES ll Solenoid valve Block on which 4 valves are mounted l 3 valve 1st stage valve heating and hot water blue 2 3 valve full outp...
Page 13: ...perature reduces the l 3 solenoid valve opens followed by the variable solenoid valve 10 Temperature adjustment is between a minimum of 40 C approx and a nominal maximum of 82 C The boiler is protected by high limit thermostats 4 and 1 6 2 Hot Water see fig 6 When there is a demand water flows in from the cold mains supply 26 through the water section part 35 of the change over valve 19 The inclus...
Page 14: ...and grey valve 9 is the security valve the blue valve 11 fixed at l 3 of max rated output the hot water black valve 12 fixed at 2 3 of maximum rated output the left hand central heating orange valve 10 which is variable up top 2 3 maximum rated output The gas admitted by the orange valve is varied by adjuster 6 see section 6 4 FUNCTIONAL FLOW DIAGRAM Summer D H W High Limit Water 113gas Stat Pump ...
Page 15: ...AL w w C I rzl SkG Hl II r SOLENOID VALVE 1 PRINTED CIRCUIT BOARD _I INTER SWITCH bk STAT HIGH LIMIT SECURITY 2 CHANGE OVER VALVE MICROSWITCHES Fig 8 k RESET SWITCH IGH RATE I IGNITION ELECTRODES P FLAME w SUPERVISION BOILER THERMISTOR HEATING b blue bk black br brown ge green gr grey or orange r red v violet w white y yellow 9 1 6 7 ...
Page 16: ...H r UJ I MESUPERVlSlON 11 1 s BOILER POTENTIOMETER II HEATING III II II IIEXTERNAL CONTRO ROOMTH I 240V 50Hz I I N SELENOID VALVE L I Ph 1 SELECTORSWITCH t 11 1111 II HIGHTENSION TRANSFORMER ig 9 tn AL q ORI Hki LlMlTSECURll Y MANUAL RESET 105 1 I ALL CABLES ARE 240V EXEPTWHERETHEYARE INDICATED24V 10 ...
Page 17: ...S 5546 gives detailed guidance on this aspect A compartment used to enclose the boiler must be designed and constructed specifically for this purpose An existing cupboard or compartment may be used provided that it is modified for the purpose Details of essential features of cupboard compart ment design are given in BS 6798 2 3 Water Circulation System 2 4 The STERLING FF is suitable for SEALED SY...
Page 18: ...livering this quantity of gas in addition to the demand from any other appliances in the house The complete Installation must be tested for soundness as described in BS 689 1 3 SYSTEMGUIDANCE 3 1 General The low water content STERLING FF boiler indudes the expansion vessels safety overheat thermostat temperature and pressure gauges and safety valve The flow temperature is adjustable and gives a no...
Page 19: ... operate correctly when all TRVs are closed see fig 17 3 6 3 3 Pump There shall be no permanent connection to the Heating System Pipework for filling or replenishing without the approval of the Local Water Authority see Byelaw No 14 and figs 12 and 13 Fdlhg point see Bs5449 Filling and recharging can be done 1 Through a temporary hose connection to mains water The boiler is fitted with a Grundfos ...
Page 20: ...s 3 10 Cylinder Where a domestic hot water cylinder is used with the STERLING FF it MUST be of the indirect and high recovery type to BS 1566 Pt 1 Single feed cyIinders are not suitable for use with this appliance Flow and return pipework to the cylinder should be in 22 mm pipe 3 11 Inhibitors and water conditioners see BS 7593 Chaffoteaux et Maury generalIy recommend the use 14 3 12 of inhibitors...
Page 21: ...outs for the production of hot water It is recommended that only a high recovery indirect cylinder is used and circumstances may from time to time dictate that a special saturated heat exchanger in an indirect cylinder may be desirable When replacing an exisiting cylinder storage system with an instantaneous type system it is essential that all redundant pipework is removed and dead legs elimiiale...
Page 22: ...mportant to select a compatible shower for the STERLING FF The following manufacturers can assist with the selection New Team Ltd Brunell Road Earlstree Industrial Estate Corby Northants NN17 2LF Meynell Valves Ltd Shaw Road Bushbury Wolverhampton West Midlands WV1 0 9LB Tel No 0536 62822 Tel No 0902 28621 Aqualisa Products Ltd Hortons Way London Road Westerham Kent TN1 6 1BT Barking Grohe 1 River...
Page 23: ...r 4 mounting screws with washers for flue turret N B i Flue accessories are not supplied as standard and must be ordered to suit see section 1 4 4 1 4 2 Positioning the boiler a Select the location for the boiler referring to the dimensions shown in 1 1 and 1 3 terminal location positions 2 4 tig 10 b Check flue length see 1 4 figs 2 and 3 c Check clearance on external wall for flue terminal posit...
Page 24: ...12 mm 4 4 in Born comer of wall e Mark waII for centre of flue opening 169 5 mm above the horizontal on side wall f DriII the waII for the flue opening using a 110 mm 4 3 in core drill g Drill 4 f g holes for A top of slot and for B 6 Fii bracket to wall using 6 mm x 50 mm wood screws Jig plate N B By using the plastic jig plate the piping system can bc completed before the boiler is mounted a Att...
Page 25: ...L ELECTRICAL COMPONENTS ORWIRING THE PIPE SHOULD BE DIRECTED DOWNWARDS IT MUST NOT DISCHARGE ABOVE AN ENTRANCE OR WINDOW OR ANY TYPE OF PUBLIC ACCESS AS THE TEMF ERATURJZ OF THE WATER BEING DISCHARGED MAY REACH 100 C held by two screws d Peel off protective paper from adhesive side of cork gasket A place on mating side of flue turret B Iiniig up with four clearance holes press together e Assemble ...
Page 26: ...ositionned inside of the cover as shown see fig 26 Fig 26 Making the electrical connection N B See Section 2 6 for electrical supply requirements THIS APPLHNCE MUST BE EARTHED a PuII out fuses A c Open door to left hand side of electrical box d Cut the cable entries to the size of the cable being used which should not be less than 0 75 mm2 e Remove cable clamp f Connect permanent live to L termina...
Page 27: ... black Installing the boiler The connection are made in the usual manner see sections 4 4 and 4 5 and the bok can now be titted see section 4 8 Fittii the condensation draia Fit the retainiig clip by removing the bottom left hand screw from the combustion chamber placing it through the faring hole in the bracket and replacing the saew with the bracket located F Place the condensation trap J into t...
Page 28: ...i 2 Honeywell Y plan Satchwelf 5 3 kOSt thermostat 5 4 Room thermostat ffow chart or Satchweff mini valves to control zones Refer to controls manufacturers literature Lie to relay coil is the wire in their literature which carries the signal to the boiler relay Room thermostat boiler terminal block boiler terminal block Fig 31 Fig 32 Fig 32 a 22 ...
Page 29: ... safety valve and is N B Valve C must be turned anti clockwise by the achieved by screwing down the head until the valve knurled shaft until it dislocates from the thread and lifts Open all low level drain cocks then pulled out horizontally to its extremity 12 Remove filter in the return isolating valve C and approximately 30 mm 1 114 ins inspect for any installation debris see section 7 4 to 2 Fi...
Page 30: ...controls are calling for heat 5 Adjust Setting pressures are given in graph figs 37 and 38 The pressure will be reduced by clockwise movement of screw increased by anticlockwise movement Now select hot water only adjust hot water regulator see fig 4 20 to miniium and open the largest volume draw off tap The gas pressure should now be the maximum as indicated in Technical Data 6 Switch boiler off a...
Page 31: ... maintained N B The by pass valve should be of the lock shield pattern The flow switch operates at approx 300 I h 1 1 gallmin Hot water adjustment A flow restrictor A is fitted on the domestic hot water outlet Adjustment of this restrictor enables regulation of the fIow rate of the D H W to suit individual installation conditions and requirements Adjustment is made by either turning the screw in a...
Page 32: ...nel K the side panels A an the rubber grommets I 2 Remove control knobs used during testing ant commissioning and tit the four grommets into the hole at the top of each side panel I 3 Fit side panels A and secure with screws at botton rear B 4 Put the control cover H in position and secure win five screws 5 Fit the front top panel over the pins at the top of the boiler C and secure with two screws...
Page 33: ...enter the current time of day 8 Day to enter the current day of the week 8 h O to enter the time hours 8 m to enter the time minutes he relevant keys are only pressed individually for aII further ntries or to check the programmed switching time CH 1 To select the standard display current status To select the relevant memory locations for ON or OFF when programming and entering in the memory Day Fo...
Page 34: ... 1 2 minutes the display contents chanI back to the current time Partial entries e g only hours are recorded in the memory b are not effective as a switching command See point 10 c To return the clock to its normal mode press the 8 key The programmed switching times are read step by step with he CH 1 key Every display content corresponds to a memo y location 1 Change 3 command called up with key C...
Page 35: ...s necessary N B Before commencing any work turn off gas at the gas inlet tap fig 34 item G and ensure that the electricity supply is disconnected Isolate water supply and drain appliance if required 7 1 7 2 To remove fimnt casing a Remove two screws A bottom rear of boiler 6 Remove screw B centre of lower front panel c Remove thermostat knob d Remove case by easing forward at bottom and Wing off l...
Page 36: ...t the flueways are completely clear c Examine electrode and clean the tip If the tip appears damaged replace electrode and lead assembly see section 8 1 d Replace all components in reverse order ensuring that the gasket between the gas section and the manifold is correctly positioned upon reassembly e Open all isolation valves and repressurise system if necessary f Recommission and check controls ...
Page 37: ...mber front panel see section 7 2 c Disconnect from electrical box by pulling off probe lead at lower left hand rear d Feed cable up through gas section H removing grommet J see fig 46a e Disconnect electrodes see section 8 1 9 Remove burner see section 7 3 g Remove screw securing probe h Replace in reverse order Fig 47 B To replace safety overheat thermostat 105 C a Remove front case see section 7...
Page 38: ... are clamped inside the box N B Refer to fig 9 for colour codes To replace the flow switch assy a Remove air separator see section 8 13 b Disconnect high pressure tube at union A c Disconnect low pressure tube at union B d Replace reverse order e Check for leaks To replace vent a Remove front case see section 7 1 b Isolate from cold mains water supply A open an hot water outlet and drain down from...
Page 39: ... PCB and earth wire f Unplug connector to change over valve at PCB g Unplug connector from fan at PCB h Remove one screw D and two screws E Electrical box support bracket to lower chassis see fig 53 1 Carefully ease electrical box forward to allow access to tlow switch lead also to electrode at bottom rear of bOX j Disconnect lead from flow switch at connector k Disconnect electrode from rear of e...
Page 40: ...sition to one side g Remove front tube 1 from change over valve unclip thermometer sensor unclip high limit thermostat h Remove flow pressure tube 2 from C 0 V to ffow switch N B Swing microswitch box to give access to union nuts j Remove rear tube 4 from C 0 V to secondary heat exchanger k Unscrew union nut 5 of mains water inlet to C 0 V I Unscrew heating flow tube nut 6 from C 0 V m Unscrew uni...
Page 41: ...connection at union D at pump outlet j Pull pump complete with volute forwards and remove k Disconnect union nut at base of air separator F m Ease air separator forward and disengage integral peg from chassis bracket q Replace in reverse order Ensure that washer is replaced in lower union of separator r Open flow and return valves Re pressurise system if necessary Fig 59 To replace themistor a Rem...
Page 42: ...ns water supply drain t om valve beneath the change over valve see section 8 11 fig 56 H c Remove clip which retains phial in wet pocket d Remove phial from pocket e Remove electrical box front cover see section 8 11 c f Ease thermostat C off moulded pegs and pull of spade connections g Feed capillary through the control box having removed the split grommet h Replace in reverse order Polarity imma...
Page 43: ...4 and 5 f Remove two screws A g Slide PCB slight upwards to disengage guide h PuII PC B forward i Replace in reverse order Vn Fig 64 17 18 9 1 11 6 13 8 1 Summer winter Switch 7 D H W Thermostat 13 Igniter 2 Pump Capillary 14 D H W Thermostat 3 Earth 8 Change Over Valve 15 Boiler Thermistor 4 LEDS 9 Time clock 16 Limit Thermostat 5 CH Limit Thermostat 10 Solenoid Gas Valve 17 Fuse 6 Water Flow Swi...
Page 44: ...2 A B C and D c Remove burner see section 7 3 d First slide out side linings followed by rear which is removed by easing upwards and sliding out from bottom e Replace in reverse order To replace fan assembly a Remove case see section 7 1 b Remove outer front panel see section 7 2 c Remove right hand side sealed chamber panel see section 8 8 e PuII off 3 spade connections from fan r Remove 2 screws...
Page 45: ... nipple c Remove two screws retaining pressure switch B d Replace in reverse order To re pressurise expansion vessel a Remove case see section 7 1 b Close heating flow and return valves and drain boiler through safety valve see section 6 2 fig 34 F c Remove protective cap and check pressure on Schroeder valve with gauge N B The setting pressure is 0 65 bar 9 5 psi d To re pressurise use car foot p...
Page 46: ...t ont panel see section 7 2 c Remove burner see section 7 3 d Replace in reverse order ensuring that the gasket is correctly positioned between the injector cover plate and the manifold Fig 73 To replace the bumer manifold assembly a Remove the front case see section 7 1 b Remove the combustion chamber front panel to expose the burner manifold see section 7 2 a to c c Remove the two screws Fl and ...
Page 47: ...pansion vessel Q Replace in reverse order engaging the thread of the ffexible pipe before screwing fully home screws B The vessel must be central on the front panel g Re pressurise expansion vessel see section 8 23 h Open flow and return valves If necessary repressurise system See section 6 2 Fig 75 Fig 76 A B To replace viewing window a Remove front case see section 7 1 b Remove combustion chambe...
Page 48: ... gas section h Remove two screws R retaining gas section to combustion chamber base i Remove gas section by pulling forward j Reassemble in reverse order and check for gas soundness Fig 77 To replace the thermometer a Remove the front case see section 7 1 6 Unclip and remove thermometer sensor from flow pipe A see fig 78 c Withdraw gauge B d Replace in reverse order Fig 78 To replace time clock a ...
Page 49: ...on 7 6 c Ensure that the boiler is completely drained and the pressure gauge is reading zero 0 d Undo the grub screw A and remove the complete assembly by carefuly pulling it in a downwards direction e Replace in reverse order r Ensure that the valve is in the close position and repressurise system see section 6 2 g Open heating flow and return valves h Check for leaks 43 ...
Page 50: ...ition heating heating red lead manual reset energised No i b v water flow switch Yes A link 5 Ye l L D H W security solenoid open 1st stage solenoid open high tension transformer energised J high tension transformer energised I 9 stream of sparks NO T 5s Yes No t l Yes 1 stream of sparks 1 t 1time delay sec maxi 1 2nd stage solenoid open 2nd stage solenoid open 44 ...
Page 51: ... supply switched on t LCI Set selector swtch to central heatmg END i Vent at air separator if Isolating valves open and all ra diators valves open RMtif I t Remove plugs from board and chedc continuity across following a Black and orame wires to change o ervahw b Water flow switch black leads c CH limit stat Made leads d CH control SM red and Ma Is there continuity aaoss all components I 1 45 ...
Page 52: ...N CONJUNCTION WITH SECTIONS 9 1 9 2 START t END 4 1 domestic hot water thermostat t YES t No I connection from printed circuit board jbla andblwlsads 1 f Is there continuity across Chedc venturi for blockage Ensure all isolating valves and stop co open I Replace if necessary 46 ...
Page 53: ...ssembled flue duct 4 Check and reassemble see section 4 10 1 4 4 VI Fan incorrectly located 5 Remove and refit correctly see section 8 21 vi Combustion chamber front cover not sealing 6a Tighten 6b Replace sealing strip vii Heat exchanger fins blocked 7 Clean see section 7 5 viii Neoprene gasket in turret not crrectly fitted 8 Fit or refit see section 4 10 or missing 5 Central heating low flow tem...
Page 54: ...ter internal water leak i Air in system ii Air in separator iii Debris in pump iv Water filter blocked 48 REMEDY Ia Check and if omitted fit by pass see section 6 6 lb Purge by venting radiators a Repressurise to 1 bar cold see section 3 6 b Replace pump head see section 8 10 3 Clean and replace see section 7 5 4 Remove and reposition see section 4 5 ia Descale ib Replace see section 8 8 ia Check ...
Page 55: ... calibration iii By pass if fitted not regulated iv Blocked heat exchanger VI Temperature differential setting incorrect i Defective printed circuit board 12 Loss of pressure I 13 Gain in pressure shown on gauge 1 Leak on system ii Leak on appliance 0 Filling loop still fitted and letting by ii Blockage in expansion chamber flexible hose iii Secondary heat exchanger water to water internal water l...
Page 56: ...Chaffoteaux et Mauty Limited Trench Lock Trench Telford Shropshire TFI 4SZ Telephone 01952 222727 Fax 01952 243493 Looking Good Heating Better fl 01939 232 796 ESPOI 5 ...
