British Gas 330 Operating manual

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To beleftwiththeuser
Instructions for Use
Installation and Servicing
High Efficiency
Condensing Boiler
0020008877-04 08.06
12373
G.C. No. 41-047-75
British Gas
330
Customer Care Line Tel: [phone]

2
0020008877-04
MAINTENANCE
INSTRUCTIONS
INTRODUCTION
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
Contents
The instructions consist of three parts, User, Installation and Servicing Instructions.
The instructions are an integral part of the appliance and must, to comply with the current
issue of the Gas Safety (Installation and Use) Regulations, be handed to the user on
completion of the installation.
CONTENTS DESCRIPTION SECTION PAGE No.
Important Information 3
General Information 4
Appliance Safety Devices 5
Maintenance 5
Operating the Boiler 6
Technical Information 1 7
Boiler Location and Ventilation 2 9
Flue Location and Ventilation 3 10
Water System 4 12
Installation Preparation 5 14
Boiler Fixing 6 15
Gas, Water and Condensate Connections 7 16
Flue Preparation Telescopic and Standard Flue 8 18
Electrical Connections 9 21
Commissioning 10 22
Servicing 11 26
Fault Finding 12 31
Replacement of Parts 13 35
Manual Handling 14 40
Spare Parts 15 41
Declaration of conformity 16 43

30020008877-04
Important Information
Control of Substances Hazardous to Health
UnderSection6ofTheHealthandSafetyatWorkAct1974,we
arerequiredtoprovideinformationonsubstanceshazardousto
health.
The adhesives and sealants used in this appliance are cured
and give no known hazard in this state.
Insulation Pads / Ceramic Fibre
Thesecancauseirritationtoskin,eyesandtherespiratorytract.
If you have a history of skin complaint you may be susceptible
to irritation. High dust levels are usual only if the material is
broken.
Normalhandlingshouldnotcausediscomfort,butfollownormal
good hygiene and wash your hands before eating, drinking or
going to the lavatory.
Ifyoudosufferirritationtotheeyesorsevereirritationtotheskin
seek medical attention.
Electrical Supply
The boiler must be earthed.
All system components shall be of an approved type and all
wiring to current I.E.E. wiring regulations.
External wiring must be correctly earthed, polarised and in
accordance with the relevant standards.
In GB this is BS 7671.
In IE this is the current edition of I.S.813 "Domestic Gas
Installations".
The boiler must be connected to a permanent 230V ac, 50Hz
supply.
Connectionofthewholeelectricalsystemoftheboiler,including
any heating controls, to the electrical supply must be through
one common isolator and must be fused 3 Amp maximum.
Isolation should be by a double pole switched fused spur box,
withaminimum gapof3mm forbothpoles. The fusedspurbox
should be readily accessible and preferably adjacent to the
appliance. It should be identified as to its use.
Alternatively connection can be made through an unswitched
shuttered socket and 3A fused 3-pin plug both to the current
issue of BS 1363 may be used, provided they are not used in a
room containing a bath or shower.
Thecoloursofthreecoreflexiblecableare,blue-neutral,brown
- live, green and yellow - earth.
Gas Category
The boiler is of the I2H category for use only with
G20 Natural Gas.
Gas Safety (Installation and Use) Regulations
In your own interests and that of safety, it is the Law that ALL
gas appliances are installed by a competent person in
accordance with the current issue of the above regulations.
Testing and Certification
Theboileristestedandcertificatedforsafetyandperformance.
Itis,therefore, important that no alteration ismadeto the boiler
unless approved, in writing, by British Gas.
Anyalterationnotapprovedby BritishGas, couldinvalidatethe
certification, boiler warranty and may also infringe the current
issue of the statutory requirements.
CE Mark
ThisboilermeetstherequirementsofStatutoryInstrument,No.
3083 The Boiler (Efficiency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on
the efficiency requirements for new hot water boilers fired with
liquid or gaseous fuels.
TypetestforpurposesofRegulation5certifiedby:Notifiedbody
0087.
Product/production certified by: Notified body 0086.
The CE mark on this appliance shows compliance with:
1. Directive90/396/EEContheapproximationofthelawsofthe
Member States relating to appliances burning gaseous fuels.
2. Directive73/23/EEContheharmonisationoftheLawsofthe
Member States relating to electrical equipment designed for
use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the Laws of
the Member States relating to electromagnetic compatibility.
WARNINGS
Gas Leak or Fault
Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e. smoking, blowlamps, hot air
guns etc. Do not operate electrical lights or switches either on or off. Open all doors and windows, ventilate the area. Call
the British Gas Emergency Service telephone number: 0800 111 999.
Sheet Metal Parts
This boiler contains metal parts (components) and care should be taken when handling and cleaning,
with particular regard to edges.
Sealed Components
Under no circumstances must the User interfere with or adjust sealed parts.

4
0020008877-04
General Information
General Note
This boiler is a wall hung high efficiency condensing boiler,
designed to provide central heating from a fully pumped open-
vented or sealed water system with a fully indirect cylinder.
Once the controls are set the boiler operates automatically.
Pleaseread theseinstructionsand followthem carefullyforthe
correct installation and economical use of your boiler.
Water Treatment
Inthecaseofanexistinginstallation,it isESSENTIALthatprior
toinstallingthenewboilerthesystemisthoroughlyflushed.For
optimum performance after installation of a new system, the
boilerand its associated centralheatingsystem should also be
flushed. Flushing should be carried out in accordance with
BS7593:1992usingacleansersuchasSentinelX300orX400,
Fernox Superfloc or Salamander corrosion guard cleaner.
For long-term corrosion protection, after flushing, an inhibitor
suitable for stainless steel exchangers should be used, refer to
the current issue of BS 5449 and BS 7593 on the use of
inhibitors in central heating systems. Examples are Sentinel
X100 Fernox or Salamander corrosion guard inhibitor.
We do not recommend filling using artificailly softened water.
Compartment or Cupboard Installations
If the boiler is fitted into a compartment or cupboard it does not
require ventilation openings.
Do not use the compartment or cupboard for storage.
Clearances
If fixtures are positioned close to the boiler, space must be
left as shown in diagram 2.1. Enough space must also be
left in front of the boiler to allow for servicing.
Condensate Drain
Thecondensatedrain, seesection7.3, mustnotbemodifiedor
blocked.
Pluming from flue terminal
Like all condensing boilers this appliance will produce a plume
of condensation from the flue terminal in cool weather. This is
due to the high efficiency and hence low flue gas temperature
of the boiler. It is normal and not a fault indication.
Cleaning
The boiler casing can be cleaned using a mild liquid detergent
with a damp cloth, then a dry cloth to polish.
Do not use any form of abrasive or solvent cleaner as you may
damage the paintwork.
Electrical Supply
If the mains electricity and gas are to be turned off for any long
periods during severe weather, it is recommended that the
whole system, including the boiler, should be drained to avoid
the risk of freezing. Make sure that, if fitted, the immersion
heater in the cylinder is switched off.
If you have a sealed water system contact your installation/
servicingcompanyasdraining,refillingandpressurisingMUST
be carried out by a competent person.
Gas Supply
NOTE: This appliance is factory set at 18kW output.
On completion of the adjustment, the inlet working pressure of
the appliance should be checked to ensure a steady inlet
working pressure of 20mbar is achieved.
Thermal Stores
This appliance is suitable for installation with thermal stores,
however,theapplianceshouldbeadjustedtogivethemaximum
31kW output.
IMPORTANT: Ifthesealonthe'Pmax'potentiometerisbroken
thegassupply,withoutexception,mustbecapableofdelivering
31.3kW input.
Manual Handling
IMPORTANT:WithregardstotheManualHandlingOperations,
1992 Regulations, the following lift operation exceeds the
recommended weight for a one man lift, refer to Section 14. for
more information.

50020008877-04
Servicing
For the continued efficient and safe operation of the boiler it is
recommendedthatitischeckedandservicedatregularintervals.
The frequency of servicing will depend upon the installation
conditions and usage, but in general, once a year should be
enough.
If this appliance is installed in a rented property in the UK there
is a duty of care imposed on the owner of the property by the
current issue of the Gas Safety (Installation and Use)
Regulations, Section 35.
Servicing/maintenance should be carried out by a competent
person in accordance with the rules in force in the countries of
destination.
To obtain service, please contact British Gas’s own service
organisation using the telephone number on the front cover of
this booklet.
Please be advised that the installation engineer on completion
of commissioning and servicing should complete the British
Gas logbook.
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boilerLogbook. YoucancheckyourinstallerisCORGIregistered
by calling CORGI direct on: - 01256 372300.
Appliance Safety Devices - User Instructions
Electrical Supply Failure Reset Switch
The boiler will not work without an electrical supply.
Normaloperationoftheboilershouldresumewhentheelectrical
supply is restored.
Reset any external controls, to resume normal operation of the
central heating.
If the boiler does not resume normal operation turn the mains
reset switch off and on. If the boiler does not resume normal
operation after this the overheat stat may have operated.
Overheating Safety
In the event of the boiler overheating the safety devices will
cause a safety shutdown. If this happens, call your Installation/
Servicing company.
Frost Protection
Theappliancehas abuiltinfrostprotectionprogrammeaslong
as the electricity and gas are left switched on.
This device operates the burner and system pump when the
temperature inside the boiler falls to 30C.
Any other exposed areas of the system should be protected by
a separate frost thermostat.
Condensate Blockage
Asasafetyfeaturetheboilerwillstopworkingifthecondensate
trap and siphon drain becomes blocked. During freezing
conditions this may be due to the forming of ice in the pipe
external to the house. Release an ice blockage by the use of
warmclothsonthepipe. Theboilershouldthenrestart. Contact
your installation/servicing company if the fault persists.
Maintenance - User Instructions
Spare Parts
REMEMBER:Whenreplacingapartonthisappliance,useonly
spare parts that you can be assured conform to the safety and
performance specification that we require. Do not use
reconditionedorcopypartsthathavenotbeenclearlyauthorised
by British Gas.
If replacement parts are required contact British Gas’s own
service organisation using the telephone number on the front
cover of this booklet.
Pleasequotethenameoftheappliance,thisinformationwillbe
on the name badge on the front of the appliance.
IfindoubtseekadvicefromBritishGas’sownserviceorganisation
using the telephone number on the inside front cover of this
booklet.

6
0020008877-04
Operating the Boiler - User Instructions
12359
Diagram 1
CONTROLS
FASCIA MAINS RESET
SWITCH
DIGITAL
DISPLAY
CENTRAL HEATING
WATER TEMPERATURE
CONTROL KNOB
OPERATION OF THE BOILER
Sealed Water Systems
CAUTION. A sealed water system must be filled and pressurised prior to use.
Only light the boiler when you are sure that the system and boiler have been filled and pressurised.
The pressure should be at least 0.7 bar, anything less than this figure could indicate a leak and you MUST contact your installer
or British Gas's own Customer Care Line using the telephone number on the front cover of this booklet.
All Systems
Check that the electrical supply to the boiler is ON at the external isolator.
Set any remote controls as required.
USER CONTROLS
Do not operate the boiler without water.
● Slide the mains reset switch to the ON position (I).
The control light will illuminate (green) indicating the boiler is lit, diagram 1.
● The temperature of the central heating water can be adjusted by turning the central heating water temperature control knob
to desired setting between 'Min' and 'Max', diagram 1.
'Max' is approximately 82°C (180°F)
The digital display, diagram 1, shows the temperature of the appliance when the
appliance is running and in standby.
A fault is indicated by a RED flashing control light and flash fault code on digital display.
To Reset
● Slide the mains reset switch to 0. Wait for 5 seconds.
Slide mains reset switch to I.
If the fault persists contact your installer/service provider.
It should be noted that this is a fan flue appliance and fan operation may be heard.
To Turn the Boiler Off
● There is a mains reset switch on the right hand side of the controls fascia.
However, it is preferable to leave the electrical supply on whenever possible to permit
operation of the built-in frost protection and daily pump exercise.
CONTROL
LIGHT

70020008877-04
Diagram 1.1
13436
1.1 IMPORTANT NOTICE
Theboilerissuppliedinonecarton,whichincludesafittingsand
documentation pack.
Thisboiler isforuse on Natural Gas (G20) asdistributed inthe
United Kingdom and Ireland and cannot be used on any other
gas.
Where no British Standards exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
Theinstallationofthisboilermustbecarriedoutbyacompetent
person in accordance the rules in force in the countries of
destination.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
1.2 Statutory Requirements
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB the installation of the boiler must be carried out by a
competent person as described in the following regulations:
The manufacturer’s instructions supplied.
The Gas Safety (Installation and Use) Regulations.
The appropriate Buildings Regulations either The Building
Regulations,TheBuildingRegulations(Scotland),TheBuilding
Regulations (Northern Ireland).
The Water Fittings Regulations or Water byelaws in Scotland.
The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).
1Technical Information
The Current I.E.E. Wiring Regulations, sixteenth edition.
British Standard 7671:2001, requirements for electrical
installations.
In IE, the installation must be carried out by a competent
person and installed in accordance with the current edition of
I.S.813 "Domestic Gas Installations", the current Building
Regulationsandreferenceshouldbe madeto thecurrentETCI
rules for Electrical Installation.
In GB the following Codes of Practice apply:
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1,
BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593.
In IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
NOTE: For further information, see the current issue of the
Building Regulations, approved document L1 ( in the UK) and
the following current issues of:
1) Central heating system specification (CheSS) and
2) Controls for domestic central heating system and hot water.
BRECSU.
Certification
This boiler certificated to the current issue of EN 483 for
performance and safety.
It is important that no alteration is made to the boiler, without
permission, in writing, from British Gas.
Any alteration that is not approved by British Gas, could
invalidatethewarrantyandcouldalsoinfringethecurrentissue
of the Statutory Requirements.
RETURN FLOW
375
75
73
54
610
53
48
113.5
13 133
48
CONDENSATE
TRAP OUTLET
GAS GAS
C
L
BOILER
C
L
FLUE
176 334
33
THIS DIMENSION
CAN BE INCREASED
TO 600 MAX.
CONDENSATE
TRAP OUTLET
30

8
0020008877-04
1Technical Information
1.3 Gas Supply
The gas installation shall be in accordance with the relevant
standards.
In GB this is BS6891.
In IE this is the current edition of I.S.813 "Domestic Gas
Installations".
The supply from the governed meter must be of adequate size
toprovideasteadyinletworkingpressureof20mbar(8inwg)at
the boiler.
Oncompletion,testthegasinstallationforsoundnessusingthe
pressure drop method and suitable leak detection fluid, purge
in accordance with the above standard.
NOTE: This appliance is factory set at 18kW output.
IMPORTANT: Ifthesealonthe'Pmax'potentiometerisbroken
thegassupply,withoutexception,mustbecapableofdelivering
31.3kW input.
If this appliance is to be used with a thermal store it should be
adjusted to the maximum output and the gas supply must be
capable of delivering 31.3kW input.
On completion of the adjustment, the inlet working pressure of
the appliance should be checked to ensure a steady inlet
working pressure of 20Mbar is achieved.
1.4 Technical Data
All dimensions are given in millimetres (except as noted).
See diagram 1.1 and Tables 1 and 2.
The data label is positioned on the inner door, refer to
diagram 1.2.The appliance data label must be completed to
indicate the maximum output using the rate indicating label
provided in the literature pack.
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is:
Class 'A'.
ThevalueisusedintheUKGovernment's StandardAssessment
Procedure (SAP) for energy rating of dwellings. The test data
fromwhichithasbeencalculatedhasbeencertifiedbyAdvantica.
1.5 Condensate Drain
A plastic drain pipe must be fitted to allow discharge of
condensate to a drain.
Condensate should, if possible, be discharged into the internal
household draining system. If this is not practical, discharge
can be made externally into the household drainage system or
a purpose designed soak away, see Section 7.3 for more
details.
Diagram 1.2
12431
m3/h ft3/h
3.31 117
2.54 90
1.90 67
1.59 56
1.27 45
0.67 24
Case Off 9.1 +0.3 -0.3
Case On 9.3 +0.3 -0.3
APPROXIMATE GAS RATE
TABLE 2
BURNER
%CO2
OUTPUT
31 kW
24 kW
18 kW
15 kW
12 kW
MINIMUM
TOTAL WEIGHT 33kg
GAS CONNECTION Rc1/2(1/2in BSPT)
WATER CONNECTION 22mm. copper
ELECTRICITY SUPPLY 230V~50Hz fused 3A
ELECTRICAL RATING 60W
INTERNAL FUSE RATE Main PCB 630mAT
TABLE 1
Manufactured exclusively for British Gas by Glow-worm
330 HIGH EFFICIENCY CONDENSING BOILER
2000467001-02
12.916.020.225.934.6
HEAT INPUT NETT Q = kW
HEAT OUTPUT NETT Q = kW
HEAT OUTPUT CONDENSING = kW
MINIMUM
MODULATION
FACTORY SETTING
47±136±129±123±119±1
6.712.115.218.224.331.3
6.312.015.018.024.031.0
MINMAX
RANGE RATING
INDICATE SETTING
FAN SETTING
REFER TO INSTRUCTIONS FOR
ADJUSTMENT METHOD
SERIAL No.
GC No.41-047-75
0086
87/BP/32
GB IE
INJECTOR:
WATER CIRCUIT PMS = 3bar
N/A - DOES NOT APPLY
TYPE :
EN437 IP X4D
C 13, C 33, C 53
NOx Class 5
230V~50Hz 60W fused at 3A For use on
I
2H
-G20-20mbar This boiler is intended
exclusively to be installed on a gas supply
with a governed meter

90020008877-04
2 Boiler Location andVentilation
Diagram 2.1
12360
†
MINIMUM CLEARANCE FROM
PERMANENT SURFACES
† A removable compartment door can be
placed at least 5mm in front of the appliance.
55
600
150 5
20 20
200
2.1 Boiler Location
This boiler is not suitable for outdoor installation.
This boiler may be installed in any room, although particular
attention is drawn to the installation of a boiler in a room
containing a bath or shower where reference must be made to
the relevant requirements.
Thisboilerissuitableforinstallationinbathroomzones2and3.
In GB this is the current I.E.E. WIRING REGULATIONS and
BUILDING REGULATIONS.
InIE reference shouldbemade to thecurrent edition ofI.S.813
"Domestic Gas Installations" and the current ETCI rules.
The boiler must be mounted on a flat wall, which is sufficiently
robusttotakeitstotal weight,see Table1. Section1.Technical
Information.
2.2 Clearances
The boiler should be positioned so that at least the minimum
operationalandservicingclearancesareprovided,seediagram
2.1.
Additional clearances may be beneficial around the boiler for
installation and servicing.
For flue installations where external access is not practicable,
consideration should be given for the space required to insert
theflueinternally,whichmaynecessitateclearancelargerthan
those specified in diagram 2.1.
2.3 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it should
be fitted in accordance with the Institute of Gas Engineers
document IGE/UP/7/1998 and BG Operational Procedures,
Part 19 Building and Kitchen Work, Section 7 - Timber Frame
Constructions.
2.4 Room Ventilation
The boiler is room sealed, so when it is installed in a room or
space, a permanent air vent is not required.
2.5 Compartment Ventilation
Dueto thehigh efficiencyand hencelow casingtemperature of
thisboiler,cupboardorcompartmentventilationisnotnecessary.
Leave existing air vents.

10
0020008877-04
3 Flue Location andVentilation
3.1 Flue Options
This boiler is suitable for concentric Horizontal and Vertical
flues,elevatedhorizontalandverticaltwin,allarefittedontothe
top of the boiler.
These instructions describe the use of the standard and
telescopic horizontal flues.
The instructions for all other flues will be contained in their
packs.
3.2 Flue Length
The maximum permissable horizontal flue length is 10 metres
plus the flue terminal, this can be achieved by use of the
accessories,howevershouldanadditional90oor2x45oelbows
be used then the length MUST be reduced by 1metre.
When extension pipes are used the flue system must be
designed to have a continuous fall to the boiler of at least 2.5o
44mm/metretoallowcondensatetorunbackintotheboilerand
out via the drain.
The flue can be installed from inside the building, when access
to the outside wall face is not practicable.
Thediagrams3.1to3.4describethelengthsachievablewithout
the use of extensions or elbows.
A
Max. distance from outside
wall face to min clearance.
LH - 458mm
RH - 561mm
Min. distance from outside
wall face to min clearance.
LH/RH - 75mm
L
FLUE
C
Max flue length 717mm
136239
20mm
min.
clearance
A
OUTSIDE
WALL FACE
87min
NOTE. If necessary, it is permitted to
increase this dimension to 600mm max.
INTERNAL
SURFACE
L
FLUE
C
Max flue length 589mm
136239
20mm
min.
clearance
A
A
Max. distance from outside
wall face to min clearance.
LH - 330mm
RH - 433mm
Min. distance from outside
wall face to min clearance.
LH - 125mm
RH - 228
OUTSIDE
WALL FACE
87min
NOTE. If necessary, it is permitted to
increase this dimension to 600mm max.
INTERNAL
SURFACE
Diagram 3.1 Diagram 3.3
Diagram 3.2 Diagram 3.4
TOP REAR FLUE - TELESCOPIC
BOILER
MOUNTING WALL
OUTSIDE
WALL FACE
208 min. to 413 max.
NOTE. If necessary, it is permitted to increase
this dimension to 600mm max.
WALL THICKNESS
87min 112
176
13162
TOP REAR FLUE - STANDARD
13161
WALL THICKNESS
75 min. to 540 max.
87min 112
176
BOILER
MOUNTING WALL
OUTSIDE
WALL FACE
NOTE. If necessary, it is permitted to increase
this dimension to 600mm max.
TOP SIDE FLUE - TELESCOPIC
13389
13388
TOP SIDE FLUE - STANDARD

11 0020008877-04
Diagram 3.5
*
*
‡
‡
Diagram 3.6
TERMINAL GUARD
3 Flue Location andVentilation
12325
SITING DIMENSIONS FOR
FANNED FLUE TERMINALS POSITION
HORIZONTAL FLUES
ADIRECTLY BELOW AN OPENING,
AIR BRICK, OPENING WINDOWS 300 300
BABOVE AN OPENING, AIR BRICK,
OPENING WINDOWS 300 300
CHORIZONTALLY TO AN OPENING,
AIR BRICK, OPENING WINDOWS 300 300
DBELOW GUTTER, DRAIN/SOIL PIPE 25 75
EBELOW EAVES 25 200
FBELOW A BALCONY OR CAR PORT 25 200
GFROM VERTICAL DRAIN PIPES AND
SOIL PIPES 25 75
HFROM INTERNAL/EXTERNAL CORNERS 25 300
HTO A BOUNDARY ALONGSIDE THE
TERMINAL 300 300
IABOVE ADJACENT GROUND OR
BALCONY LEVEL 300 300
JFROM SURFACE OR A BOUNDARY
FACING THE TERMINAL 600 600
KFACING TERMINALS 1200 1200
LFROM OPENING (DOOR/WINDOW)
IN CAR PORT INTO DWELLING 1200 1200
MVERTICAL FROM A TERMINAL 1500 1500
NHORIZONTALLY FROM A TERMINAL 300 300
VERTICAL FLUES
PFROM ANOTHER TERMINAL 600 600
QABOVE ROOF LEVEL 300 300
RFROM ADJACENT OPENING WINDOW 1000 1000
SFROM ADJACENT WALL TO FLUE 300 300
3.4 Terminal Position
The minimum acceptable siting dimensions for the terminal
fromobstructions, other terminalsand ventilationopeningsare
shown in diagram 3.5. Dimensions shown are measured from
edge of terminal.
Only one dimension from the minimum clearance should be
applied, all others should be to the nominal clearance.
The terminal must be exposed to the external air, allowing free
passage of air across it at all times.
Being a condensing boiler some pluming may occur from the
flue outlet. This should be taken into consideration when
selecting the position for the terminal.
NOTE: If necessary it is permitted to increase the terminal
protrusionthroughtheoutsidewalltogreaterthantheminimum
dimensionof87mmbutnomorethan600mm,seediagram1.1.
F‡and L‡See diagram 3.5 . Carports or similar extensions
ofaroofonly,oraroofandonewall,requirespecialconsideration
withrespecttoanyopenings,doors,ventsorwindowsunderthe
roof. Care is required to protect the roof if made of plastic
sheeting. If the carport comprises of a roof and two of more
walls, seek advice from the local gas supply company before
installing the boiler.
H*and J*See diagram 3.5 . These dimensions comply with
the building regulations, but they may need to be increased to
avoid wall staining and nuisance from pluming depending on
site conditions.
3.5 Terminal Guard
A terminal guard is required if persons could come into contact
with the terminal or the terminal could be subject to damage.
If a terminal guard is required, it must be positioned to provide
minimum of 50mm clearance from any part of the terminal and
be central over the terminal.
The guard should be plastic coated similar to that shown in
diagram 3.6.
A suitable guard is manufactured by:
Tower Flue Components
Morley Rd.
Tonbridge
Kent
TN9 1RA
Size: 280mm x 280mm x 270mm.
Min. Nom.
mm mm

12
0020008877-04
4Water System
Table 3. Flow Rate
OUTPUT MINIMUM FLOW RATE
18 773.8 litres/hr (12.9litres/min)
31 1289 litres/hr (21.5litres/min)
This is equal to 20oC differential acros the appliance.
Diagram 4.1
12430
4.1 Draining Tap
A draining tap must be provided at the lowest point of the
system,whichwillallowtheentiresystemandhotwatersystem
to be drained.
Draining taps shall be to the current issue of BS 2879.
4.2 Safety Valve
A safety valve need not be fitted to an open-vented system.
4.3 Pump
The pump should be fitted on the flow pipe from the boiler and
have isolating valves each side.
A variable duty pump should be set to give a temperature
differenceof nogreater than200C betweenthe flowand return,
with the thermostat set at “MAX”, which is about 800C, to give
a flow rate as shown in table 3.
See chart for pressure loss of the boiler, diagram 4.1.
High resistance microbore systems may require a higher duty
pump.
4.4 Flow Rate
If it is necessary to alter the flow rate, the system can be fitted
with a lockable balancing valve in the main flow or return pipes
shown as valve “A” in diagram 4.3. The flow rate through the
boiler must not be allowed to fall below that given in Table 3.
IMPORTANT Flow and Return Pipe Sizes.
Heatingcircuitflowandreturnpipesshouldbesizedasfollows.
Upto 18 kW 22mm. over 18 kW 28mm.
4.5 Bypass
Asystembypasswillberequiredfittedatleast1.5metresaway
from the boiler, refer to the current issue of the central heating
system specifications (CHeSS).
4.6 Water Treatment
Inthecaseofanexistinginstallation,it isESSENTIALthatprior
toinstallingthenewboilerthesystemisthoroughlyflushed.For
optimum performance after installation of a new system, the
boilerand its associated centralheatingsystem should also be
flushed. Flushing should be carried out in accordance with
BS7593:1992usingacleanser suchas FernoxorSalamander
products.
For long-term corrosion protection, after flushing, an inhibitor
suitable for stainless steel exchangers should be used, refer to
the current issue of BS 5449 and BS 7593 on the use of
inhibitors in central heating systems. Examples are Fernox or
Salamander products.
4.7 Open (Vented) Water System
The boiler must be supplied from an unrestricted water supply
takenfromafeedandexpansioncisternsituatedatamaximum
height of 27 metres (90ft) above the boiler.
The cold feed must be 15mm minimum size.
The vent must rise continuously and be unrestricted.
It is important that the relative positions of the pump, cold feed
and open vent are as shown in diagram 4.2.
Diagram 4.2
9235
Open (vented) system.
Recommended
relationship between
pump, cold feed and vent.
22mm (MIN.) VENT
FEED AND
EXPANSION CISTERN
15mm (MIN) COLD FEED
15mm (MIN.)
AUTOMATIC BY-PASS
RETURN
FLOW
HEATING
CYLINDER
PUMP
BOILER 150mm MAX.
1000mm
MIN.
450mm
MIN.
HEIGHT

13 0020008877-04
4Water System
Diagram 4.3
12999
4.8 Combined Feed and Vent
For combined feed and vent, a 22mm pipe must be fitted in
accordance with BS 5449.
4.9 Domestic Hot Water Cylinder
SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE
Thedomestichotwatercylindermustbeofthedoublefeedfully
indirect coil type.
Thermal Stores
This appliance is suitable for installation with thermal stores,
however,theapplianceshouldbeadjustedtogivethemaximum
31kW output.
4.10 Domestic Hot Water System - unvented
General - All domestic hot water circuits, connections, fittings
must be in accordance with the relevant standards and water
supply regulations.
For GB: Guidance G17 to G24 and recommendation R17 to
R24 of the Water Regulations Guide.
ForIE:ThecurrenteditionofI.S.813"DomesticGasInstallations".
Wherea storagesystem willnothave avent toatmospherethe
installation must comply with the building regulations and local
Water Company bylaws, see also the current issue of BS5546
and BS6700.
If fitting to an existing system the local authority should be
informed.
4.11 Sealed water Systems
Theinstallationmustcomplywiththeappropriaterequirements
ofthe current issue ofBS4814,BS5449, BS6759, BS6798and
BS7074 Part 1 and 2.
See diagram 4.3 for a suggested layout.
4.12 Safety Valve
A safety valve must be fitted to a sealed system.
It shall be preset, non-adjustable with a lift pressure of 3 bar,
incorporating seating of a resilient material, a test device and a
connection for drain.
The drain from the safety valve must be routed outside the
building, must not discharge above an entrance or window or
anytype ofpublic accessarea,be clearof anyelectricalfittings
and positioned so that any discharge can be seen.
4.13 Expansion Vessel
A diaphragm type expansion vessel, conforming to the current
issue of BS4814 (see also BS7074 Part 1 and 2) must be
connected at a point close to the inlet side of the circulating
pump, see the diagrammatic layout, diagram 4.3 unless laid
down differently by the manufacturer.
The expansion vessel volume depends on the total water
systemvolume andthe initialsystem designpressure. For any
system an accurate calculation of vessel size is given in the
current issue of BS5449 and BS7074 Part 1.
Example:Foraninitialdesignpressureof0.7bar,theminimum
total vessel volume required is 0.063 x Total System Volume.
NOTE: Ahigherinitialdesignpressurerequiresalargervolume
expansion vessel.
Guidance on vessel sizing is also given in the current issue of
BS5449and BS7074Part 1,for IErefer tothe currentedition of
I.S.813 "Domestic Gas Installations".
Thechargepressuremustnotbelessthanthestaticheadofthe
system, that is, the height of the highest point of the system
above the expansion vessel.

14
0020008877-04
Diagram 5.1
12296
SECURING
SCREW (2 OFF)
FRONT CASING
PANEL
RETAINING
LUG
(2 OFF)
TEMPORARY
CONNECTION
HOSE
UNION
HOSE
UNION
SUPPLY
PIPE
CONTROL
VALVE
CONTROL
VALVE
DOUBLE
CHECK
VALVE
HEATING
CIRCUIT
DRAIN
POINT
BOILER
RETURNFLOW
4Water System
4.14 Pressure Gauge
A pressure gauge with a set pointer and covering at least 0 to
4 bar (0 to 60 lb/in2) shall be fitted permanently to the system in
a position where it can be seen when filling the system.
4.15 Domestic Hot Water Cylinder
SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE
Thedomestichotwatercylindermustbeofthedoublefeedfully
indirect coil type. It must be suitable for working at a gauge
pressure of 0.35 bar above the safety valve setting.
4.16 Water Make-up
Provision should be made for replacing water loss from the
systemusingamakeupbottlemountedinapositionhigherthan
the top point of the system, connected through a non-return
valve to the return side of either the heating circuit or the hot
water cylinder.
Alternatively,provision formake upcanbe madeusing a filling
loop.
4.17 Filling a Sealed Water System
Provision for filling the system at low level must be made, see
diagram 4.4. There must be no permanent connection to the
mainswatersupply,eventhroughanon-returnvalve.Wedonot
recommend filling using artificially softened water.
Diagram 4.4
11680
5.1 Appliance Pack
IMPORTANT: With regards to the Health and Safety Manual
Handlingrequirements, two persons shallberequired to lift the
appliance, refer to manual handling on page 4.
Lift the boiler out of the carton
NOTE:Thefittingspackandtheflexiblecondensateoutletpipe
are located in the base polystyrene packing under the boiler
base and the bottom cover is located at the back of the boiler.
Remove both and put to one side.
Remove the polystyrene end packing pieces then carefully lay
the boiler on its back, remove the two front casing panel
securing screws and lift off the panel from two retaining lugs,
see diagram 5.1.
Remove the transit packaging behind the front panel and
discard.
Carefully place front panel and screws to one side.
5.2 Wall Template
Remove the wall template from the documentation pack and
placeinthedesiredpositiononaflatwall,givingdueconsideration
toboilerclearances,seeSection2.2,andtheflueyouarefitting.
5 Installation Preparation

15 0020008877-04
(44mm/metre)
Diagram 5.2
12046
WALL
TEMPLATE
EXTENDED SIDE FLUE
(Standard Flue type 'B' shown)
Ø 125
900
176
5 Installation Preparation
6.1 Hanging Bracket Fixing
Ifpreviouslyremoved,repositionthewalltemplateovertheflue
hole and mark the position of the fixing holes for the hanging
bracket, see diagram 6.1.
Mark and drill the fixing holes and secure the hanging bracket,
which is supplied in the polystyrene pack.
NOTE:Duetothevariedsiteconditionswedonotsupplyfixings
and advise that the installer should supply those which are
suitable.
6.2 Boiler Fixing
IMPORTANT: WithregardstotheManualHandlingOperations,
1992 Regulations, the following lift operation exceeds the
recommendedweightforaonemanlift,refertoManualHandling
section on page 4.
Lifting the boiler into position, lean the top of the boiler slightly
to the wall and position just above the hanging bracket. Lower
the boiler slowly and engage onto the hanging bracket.
Make good the final connections.
6 Boiler Fixing
Diagram 6.1
12047
WALL PLUG
(4 OFF)
SCREW No12 x 50mm
(4 OFF)
WALL
TEMPLATE
HANGING
BRACKET
5.3 Flue Hole Cutting
The standard horizontal flues are designed with an internal
fallof44mm/metretowardstheboilerfordisposalofcondensate.
Ifthestandard fluelengthaloneisbeing usedthenthe fluehole
ofdiameter105mmcanbecutinthepositionmarkedonthewall
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 176mm from the back
wall.
For installations with external access, a 105mm diameter core
drill can be used.
For installations with internal access only a 125mm diameter
core drill should be used.
Whenusingextensionpipeswiththehorizontalrearflue,acore
drillsizeof125mmshouldbeusedtoallowtheextensionpieces
to slope at 44mm/metre (2.50) towards the boiler.
For extended side flues the flue hole centre should be
determinedbyextendingthedashedinclinedlineonthetemplate
tothesidewall.This dashedlineisdrawnat 44mm/metre(2.50)
rise from the boiler. Where this line reaches the side wall, a
horizontallineshouldbemarked. Theverticalcentrelineofthe
flue should then be marked at 176mm from the back wall, see
diagram 5.2.
To allow for the flue passing through the wall at this angle a
125mmholeshouldbedrilledirrespectiveofinternalorexternal
installation.
If necessary remove the wall template whilst drilling the flue
hole.

16
0020008877-04
7 Gas,Water and Condensate Connections
Diagram 7.2
9244
FLOW
RETURN
Heating circuit flow and return
pipes should be sized as follows.
Up to 18 kW 22mm.
over 18 kW 28mm.
Compression is the
recommended fixing
for servicing. (not supplied)
Diagram 7.1
12934
FLEXIBLE
CONDENSATE
OUTLET PIPE
GAS
SERVICE
COCK
GAS
SUPPLY
PIPE IN
GAS SERVICE
COCK SHOWN IN
OPEN POSITION UNION CONNECTOR
SPIGOT
GAS SERVICE
COCK LINER
CONDENSATE DRAIN
CONNECTION
7.1 Gas Connection
Before connection check the supply of local gas.
Thegassupplycanbeconnectedfrombelow,seediagram7.1.
or through the wall at the rear of the boiler.
Refer also to section 1.2 and 1.3.
Thewholeofthegasinstallation,includingthemeter,shouldbe
inspected,testedforsoundnessandpurgedinaccordancewith
the document IGE/UP/1B.
7.2 Water Connections
Provision is made for the water connections to be made from
abovetheboiler,seediagram7.2. Thepositionisshownonthe
wall template.
Flush out the domestic hot water and the heating systems
before connecting to the boiler.
7.3 Condensate Drain Connection
Thecondensatedrainconnectionisattherearoftheboiler,see
diagram7.1. Aflexiblecondensateoutletpipeissuppliedloose
in the base polystyrene packaging. The 900 end of the flexible
condensate outlet pipe should be used to fit onto the spigot, to
discharge condensate to a drain. The drain pipe 22mm to
25mm OD. non corrosive plastic pipe should have a fall of at
least 2.50away from the boiler.
Condensateshould,ifpossiblebedischargedintothehousehold
internal drainage system. If this is not practicable, discharge
canbe allowed intothe external householddrains or apurpose
designed soak away, refer to diagram 7.3.
It is recommended that any external condensate drain pipe is
preferably of 32mm diameter, to prevent freezing in adverse
weather conditions.
Thecondensateisdischargedperiodicallyin‘slugs’bysiphonic
action.
It is not necessary to provide air breaks or extra traps in the
discharge pipe as there is already a 75mm high trap inside the
boiler.Fittingan extra trap may cause theboilersiphon to work
incorrectly.
Refer to BS5546 or BS6798 for advice on disposal of boiler
condensate.

17 0020008877-04
7 Gas,Water and Condensate Connections
INTERNAL SOIL
AND VENT STACK BOILER
Ø22mm MIN.
NO RESTRICTION
ON LENGTH
EXTERNAL SOIL
AND VENT STACK
Ø22mm MIN.
NO RESTRICTION
ON LENGTH
BOILER
BOILER
Ø22mm MIN.
EXTERNAL LENGTH
OF PIPE 3M MAX.
OPEN END OF PIPE
DIRECT INTO GULLEY
BELOW GROUND BUT
ABOVE WATER LEVEL
Ø22mm MIN.
NO RESTRICTION
ON LENGTH
BOILER
SINK
(CONSTITUTES
AIR BREAK)
BOILER
Ø22mm MIN.
NO RESTRICTION
ON LENGTH SINK
OPEN END OF PIPE DIRECT INTO
GULLEY BELOW GROUND LEVEL
BUT ABOVE WATER LEVEL.
Ø22mm MIN.
TERMINATION FROM APPLIANCE.
EXTERNAL LENGTH OF PIPE
3M MAX.
25mm MIN.
SEAL
BOTTOM OF
TUBE SEALED
Ø100mm
PLASTIC TUBE 300mm
MIN.
GROUND
(either/or)
500mm MIN.
HOLE DEPTH
400mm MIN.
LIMESTONE CHIPPINGS
2 ROWS OF 3 x 12mm HOLES AT
25mm CENTRES 50mm FROM
BOTTOM OF TUBE. HOLES TO
FACE AWAY FROM HOUSE.
External Soil and Vent Pipe or Rainwater Pipe
Internal Soil and Vent Pipe
External Termination into Soakaway
Internal Termination Downstream of
Sink Waste
Internal Termination into Combined Sink Waste
External Termination to a Gulley or Hopper
*
NOTE: PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2.5
44mm FOR EVERY 1M.
o
EXTERNAL
MAX. 3M
*NOTE: FOR EXTENDED
PIPE RUNS 32mm DIA.
PIPE SHOULD BE USED.
13000
Diagram 7.3

18
0020008877-04
8 Flue PreparationTelescopic and Standard Flue
Diagram 8.2
12842
45
o
Bend
2000460485
(2off)
90
o
Bend
2000460484
0.5m
EXTENSION
2000460481
1m
EXTENSION
2000460482
2m
EXTENSION
2000460483
VERTICAL
FLUE
ADAPTOR
A2024600
8.1 Flue Components
The components supplied in the Standard and Telescopic kit
are shown in diagram 8.1.
Additional flue accessories are available to suit your site
conditions, see diagram 8.2.
12841
Diagram 8.1
TELESCOPIC
TERMINALASSEMBLY
SEALING
COLLAR
SEALING
COLLAR
SECURING
COLLAR
FLUE
ELBOW
GASKET
(fitted)
SEALING
TAPE (telescopic only)
Top Outlet Horizontal Concentric Flue Packs:
A2043600 Horizontal telescopic flue pack.
A2043400 Standard horizontal flue pack.
STANDARD
TERMINALASSEMBLY
SCREW x 1
SCREW x 2
SCREW x 2
SCREW x 4

19 0020008877-04
8 Flue PreparationTelescopic and Standard Flue
8.3 Preparation
Telescopic:
The Telescopic Flue system MUST NOT be cut.
Adjust the flue to your required length "Y", ensure the air duct
seams line up mark the securing hole position in the air duct.
Drilla3mmdiameterholeatthisposition, takecarenottopierce
the inner flue duct. Secure with screw provided and tape the
joint, see diagram 8.5.
Standard:
Separate the flue duct from the terminal by twisting to release
the terminal catch, then pull out of the retaining seal, refer to
diagram 8.6.
The duct cutting lengths are shown in diagram 8.6.
The air duct should be cut at the opposite end to the terminal
fixing.
The terminal plastic flue duct MUST be cut at the opposite end
to the catch.
The plastic flue duct extensions MUST be cut at the opposite
end to seal.
The cut ducts must be de-burred and all filings and debris
removed.
NOTE: If you require to lubricate the seals to ease installation,
please do not use a mineral oil based grease, we would
recommend the use of water.
Diagram 8.6
12847
Diagram 8.5
12929
AIR DUCT
FLUE DUCT
13mm L
L + 11mm
L
TERMINAL
CATCH
8.2 Flue Length
Top Rear flue - Standard - with the flue elbow temporarily
fitted, measure the distance from the outside wall to the butt
joint, seediagram8.3.Ifthemeasurement'Y'exceeds652mm,
then the appropriate length of extension pipe is required. The
minimumdimensionis187mmtosuita75mmminwallthickness.
Top Rear flue - Telescopic - with the flue elbow temporarily
fitted, measure the distance from the outside wall to the butt
joint, seediagram8.3.Ifthemeasurement'Y'exceeds525mm,
thenthe appropriatelengthof extensionpipe is required, if the
dimension is less than 320mm DO NOT cut the flue, it can
project to a maximum of 600mm, if this is not desirable then a
Standard flue MUST be used and cut to length.
TopSideflue-Standard-withtheflueelbowtemporarilyfitted,
measurethedistancefromtheoutsidewalltothebuttjoint, see
diagram 8.4. If the measurement 'Y' exceeds 652mm, then the
appropriatelength of extension pipeis required.The minimum
dimension for Lhd is 270 and Rhd 167 to suit a minimum wall
thickness of 75mm.
Top Side flue - Telescopic - with the flue elbow temporarily
fitted, measure the distance from the outside wall to the butt
joint, seediagram8.4.Ifthemeasurement'Y'exceeds525mm,
thenthe appropriatelengthof extensionpipe is required, if the
dimension is less than 320mm DO NOT cut the flue, it can
project to a maximum of 600mm, if this is not desirable then a
Standard flue MUST be used and cut to length.
Diagram 8.3
12806
Diagram 8.4
13160
TOP REAR FLUE
TOP SIDE FLUE

20
0020008877-04
8 Flue PreparationTelescopic and Standard Flue
8.4 Flue Fitting (Telescopic and Standard)
Fit the rubber sealing collar behind the locating lugs on the flue
terminal, see diagram 8.7.
Push the flue assembly into the wall, externally or internally,
initiallyuntiltheendoftheassemblyprotrudesashortwayfrom
theinsidefaceofthewall. Thiswillenabletheinternaltrimring(if
required) to be positioned and allow the flue duct to be drawn
back into the flue elbow.
Secure the flue elbow in position on top of the boiler with four
torque headed screws supplied.
Drawtheflue assembly from wall and engagetheflue duct into
the elbow and butt fit between the air duct and flue elbow.
Enure alignment of the terminal.
Fit the collar into position, mark through two of the pre drilled
holes in the collar. Remove collar and drill two 3mm diameter
holes in the elbow, take care not to pierce the inner flue duct.
Fit the collar and secure with screws provided, see diagrams
8.8 standard rear, 8.9 telescopic rear, 8.10 standard side and
8.11 telescopic side.
Diagram 8.9
Diagram 8.10
Diagram 8.8 Diagram 8.11
13157
13156
13159 13158
BOILER MOUNTING
WALL FACE
DRILL AND
SCREW
COLLAR
OUTSIDE
WALL FACE
INTERNAL TRIM RING
RUBBER
SEALING
COLLAR
DRILL AND
SCREW
COLLAR
OUTSIDE
WALL FACE
INTERNAL TRIM RING
BOILER MOUNTING
WALL FACE
RUBBER
SEALING
COLLAR
L
FLUE
C
OUTSIDE
WALL FACE
DRILL
AND
SCREW
COLLAR
INTERNAL TRIM RING
RUBBER
SEALING
COLLAR
L
FLUE
C
OUTSIDE
WALL FACE
DRILL
AND
SCREW
COLLAR
INTERNAL TRIM RING
RUBBER
SEALING
COLLAR
Diagram 8.7
12977
NOTE: If the air and flue ducts have been correctly cut to the
instructionsgiveninsection8.2,therubbersealingcollarshould
fit flush with the outside wall, check this.
Slide the internal trim ring back against the wall, securing in
place with a small amount of sealant if required.