Glowworm 30ci User manual

30ci plus
Fanned Flue Combination Boiler
G.C. No. 47-047-22
To be left with the user
InstructionsforUse
InstallationandServicing
4000123944-2 07/03
Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT

2
4000123944-2
Guarantee Registration
Thank you for installing a new Glow-worm appliance in your home.
Glow-worm appliances' are manufactured to the very highest standard so we are pleased to offer our customers’ a
Comprehensive Guarantee.
This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture,
whichever is the shorter, for parts. In addition this product is guaranteed for 12 months from the date of installation or
18 months from the date of manufacture, whichever is the shorter, for labour.
The second year of the parts guarantee, from the beginning of the 13th month onwards after installation, is conditional
upon the boiler having been serviced by a CORGI registered gas installer, in accordance
with the manufacturer's recommendations. We strongly recommend regular servicing of your gas appliance, but where
the condition is not met, any chargeable spare parts or components issued within the applicable guarantee period still
benefit from a 12 month warranty from the date of issue by the manufacturer.
We recommend you complete and return as soon as possible your guarantee registration return literature, supplied in
the document envelope.
If your guarantee registration return literature is missing you can obtain a copy by telephoning
Glow-worm Service on 00 44(0)1773 828100.
RECORD YOUR GLOW-WORM APPLIANCE DIRECT BY CALLING
0208 247 9857
Customer service :
Glow-worm GB Great Britain :
Tel. [phone]
Fax. [phone]
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
Glow-worm IE Ireland:
Tel. 00 353 (0)16305757
Fax. 00 353 (0)16305724
C & F Quadrant Ltd.,
Quadrant House,
Chapelizod, Dublin 20
Technical Advice Line:
Tel. [phone]
General and Sales enquiries:
Tel. [phone]
Fax. [phone]

34000123944-2
Important Information 4
Draining and Filling 5
Appliance Introduction 5
Appliance Safety Devices 5
Maintenance and Servicing 6
Controls and Lighting 7
Programmer instructions for use 9
Technical Data 1 10
General Information 2 11
Heating System Design 3 11
Domestic Hot Water System Design 4 12
Boiler Schematic 5 13
Boiler Location, Flue and Ventilation 6 14
Fixing Jig 7 16
Boiler Preparation and System Connections 8 17
Boiler Installation 9 18
Horizontal Telescopic Rear Flue Installation 10 20
Horizontal Telescopic Top Flue Installation 11 22
Horizontal Top Flue Installation 12 24
Electrical Connection 13 26
Commissioning 14 28
BoilerSettings 15 30
Changing Gas Type 16 32
Routine Cleaning and Inspection 17 33
Fault Finding 18 37
Wiring Diagram 19 43
Replacement of Parts 20 44
Spare Parts 21 56
CONTENTS DESCRIPTION SECTION PAGE No.
SERVICING
INSTRUCTIONS
INSTALLATION
INSTRUCTIONS
INSTRUCTION
FOR USE
Contents

4
4000123944-2
Gas safety (Installation and use) Regulations
Inyourinterestsandthatofgassafety,itisthelawthatALLgas
appliancesareinstalledandservicedbyacompetentpersonin
accordancewiththeregulations.
Testing and Certification
This boiler is tested and certificated for safety and
performance. It is therefore important that no alteration is
made to the boiler, without permission, in writing, from
Hepworth Heating Ltd.
Any alteration not approved by Hepworth Heating Ltd., could
invalidate the certification, boiler warranty and may also
infringe the current issue of the Statutory Requirements. The
requirements are: The installation of this boiler must be
carried out by a competent person in accordance with the
current rules in force in the countries of destination at the
time of installation, for Ireland, install in accordance with
I.S.813 "Domestic Gas Installation". Manufacture's
instructions supplied must not be taken as overriding
statutory requirements.
CEMark
This boiler meets the requirements of Statutory Instrument
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.
Type test for purposes of Regulation 5 certified by: Notified
body0049.
Product/productioncertifiedby:Notifiedbody0049.
The CE mark on this appliance shows compliance with:
1. Directive 90/396/EEC on the approximation of the laws of
the Member States relating to appliances burning
gaseous fuels.
2. Directive 73/23/EEC on the harmonization of the Laws of
the Member States relating to the electrical equipment
designed for use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the Laws of
theMember States relating toelectromagneticcompatibility.
Control of Substances Hazardous to Health
The adhesives and sealants used in this appliance are cured
and give no known hazard in this state.
Insulation pads / ceramic fibre
These can cause irritation to skin, eyes and the respiratory
tract.
If you have a history of skin complaint you may be suscepti-
ble to irritation. High dust levels are usual only if the material
is broken.
Normal handling should not cause discomfort, but follow
normal good hygiene and wash your hands before eating,
drinking or going to the lavatory.
If you do suffer irritation to the eyes or severe irritation to the
skin seek medical attention.
The insulation is composed of non-combustible material.
Electrical Supply
WARNING: This boiler must be earthed.
All system components shall be of an approved type and shall
be connected in accordance with the current issue of BS7671
and any applicable local regulations.
All external wiring between the appliance and the electrical
supplyandearthingrequirementsshallcomplywiththecurrent
IEE Regulations.
Connection of the boiler and system controls to the mains
supplymustbethroughacommonisolatorandmustbe fused
at3A,maximum. Thismethodofconnectionmustbebyafused
doublepoleisolatingswitch,withaminimumcontactseparation
of3mmonbothpoles. Theswitchshouldbereadilyaccessible
and preferably adjacent to the appliance. It should supply the
appliance only and be easily identifiable as so doing.
Alternatively, an unswitched shuttered socket outlet and 3A
fused 3 pin plug, both to the current issue of BS1363 may be
usedprovidedthattheyarenotusedinaroomcontainingabath
or shower.
WiringtotheboilermustbePVC85oCinsulatedcable,notless
than 0.75mm2(24/0.20mm).
Gas leak or fault
WARNING: Ifagasleakorfaultexistsorissuspected,turnthe
boiler off and consult the local gas supply company or your
installation/servicecompany.
Manual Handling Guidance
Duringtheapplianceinstallationit will be necessary to employ
caution and assistance whilst lifting as the appliance exceeds
the recommended weight for a one man lift.
In certain situations it may be required to use a mechanical
handling aid.
Take care to avoid trip hazards, slippery or wet surfaces.
Heating System Controls
The heating system must be controlled as described in the
relevant part of the current issue of :
Building Regulations, approved document L1, and the
references:
1)GIL59,2000: Centralheatingsystemspecification(CheSS)
and
2) GPG 302, 2001: Controls for domestic central heating
system and hot water. BRECSU.
3) The domestic heating and hot water guide to the building
regulations 2001.
Thermostatic radiator valves may be installed, however they
must not be fitted in a room where the room thermostat is
located.
Air in the heating system
Persistent air in the heating system may indicate leaks in the
systemorcorrosiontakingplace.CallyourInstallation/Servicing
company.
Protection Against Freezing
Theappliance hasabuilt infrostprotection programmeaslong
as the electricity and gas are left switched on.
This device operates the burner and system pump when the
temperature inside the boiler falls below 60C.
Any other exposed areas of the system should be protected by
a separate frost thermostat.
Important Information

54000123944-2
The30ciplus boilerisawallmountedmodulatingcombination
boiler with electronic ignition providing central heating and
instantaneous hot water.
The boilers are equipped with a litre domestic hot water
storage vessel that ensures maximum hot water temperature
stabilityduringdomesticdemand.
TheboilerisoftheII2H3+ categoryforusewithNaturalGas(G20)
asdistributedintheUnitedKingdom,orButane(G30),Propane
(G31) with the appropriate conversion kit.
Theboilerhasafanassistedbalancedfluewhichbothdischarges
the products of combustion to and draws the combustion air
from the outside of the room.
Both the central heating and domestic hot water temperature
are user adjustable.
Domestic hot water demand always has priority over heating
demand.
The boiler is designed for use as part of a sealed water central
heating system with fully pumped circulation. The pump,
expansion vessel and associated safety devices are all fitted
within the boiler.
Theboiler can be installed against either anexternal wall or on
anadjacentinsidewall,thatis,thefluesystemwillpassdirectly
to the rear or to either side to the terminal fitted on the outside
wall face.
This boiler may be installed in any room, although particular
attention is drawn to the installation of a boiler in a room
containingabath or shower where reference must bemadeto
the relevant requirements.
Any electricalswitchor boiler control utilising mains electricity
shouldbe placedsothatitcannotbetouchedbyapersonusing
the bath or shower.
In GB this is the current I.E.E. WIRING REGULATIONS and
BUILDING REGULATIONS.
InIEreferenceshould bemadetothecurrent editionofI.S.813
"Domestic Gas Installations" and the current ETCI rules.
Theseinstructionsshouldbecarefullyfollowedforthesafeand
economicaluseofyourboiler.The 'UserControlsandLighting'
section describes how to safely use the boiler.
Note: The boiler serial number is marked on the data label
attached to the rear of the control box.
Flue options
There are various flue systems to choose from, for detailed
information refer to flue options guide, which is available
from your nearest stockist.
Accessories
A range of accessories are available.
For further information contact your supplier.
Draining and Filling
Appliance Introduction
Diagram 1
BOILER
DRAIN
VALVE
11900
➜
(a) (b)
(c)
0.4
bar
Caution: The boiler is installed as part of a sealed system
which must only be drained and filled by a competent person.
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, refer to diagram 1, should
bedrainedtoavoidtheriskoffreezing. Makesurethat,iffitted,
the immersion heater in the cylinder is switched off.
If in doubt, consult your servicing company.
• If the boiler loses water: the pressure will be indicated (a)
and the boiler ON indicator (b) will flash red indicating a fault.
Fillthesystembythefillingdevice(c)atthebottomoftheboiler
until the pressure gauge reads 1.0 bar.
A mains inlet pressure of 2.0 bar is required to reach a fill
pressure of 1.0 bar.
Reset boiler: referto diagram 2,switchOn/Offto ( 0 ),waitfor
five seconds. Switch On/Off to ( I ) to reset the appliance.
• Warning: Take care not to overfill the boiler.
Atapressureof2.5baroraboveindicatingoverpressure,the
boiler ON indicator (b) will flash red indicating a fault. The
pressure must be reduced to 1.0 bar by opening the drain
valve,refertodiagram1. Ifthefaultcontinuescalltherelevant
Servicing organisation or Glow-worm Service using the
telephone number on the inside front cover of this literature.

6
4000123944-2
Air flow rate safety device
Iftheflueisobstructed,evenpartially,thebuiltinsafetysystem
will turn the boiler OFF, the fan will continue to run. The boiler
will be ready to operate when the fault has been cleared.
Overheating safety
In the event of the boiler overheating the safety devices will
causeasafetyshutdown.Ifthishappens,callyour Installation/
Servicing company.
Electrical supply failure
Theboilerwillnotoperatewithoutanelectricalsupply. Normal
operation of the boiler should resume when the electrical
supply is restored.
Reset any central heating system controls, to resume normal
operation.
If the boiler does not resume normal operation turn the mains
reset switch off and on. If the boiler does not resume normal
operation it is advisable to consult your installation / servicing
company.
Frost protection
The appliance has a built in frost protection device that
protects the boiler from freezing. With the gas and electric
supplies ON and irrespective of any room thermostat setting,
the frost protection device will light the boiler when the
temperature of the boiler water falls below 6°C.
When the temperature reaches 16°C, the boiler stops.
Anyotherexposedareasofthesystemshouldbeprotectedby
a separate frost thermostat.
Heating safety valve
CAUTION:Aheatingsafetyvalvewithadischargepipeisfitted
to this boiler.
The valve MUST NOT BE TOUCHED except by a competent
person.Ifthevalvedischargesatanytime,switchtheboileroff
andisolateitfromtheelectricalsupply.Contactyourinstallation/
servicecompany.
Domestic Hot Water safety valve
CAUTION: Adomestichotwatersafetyvalve,withadischarge
pipe is fitted to this boiler.
The valve MUST NOT BE TOUCHED except by a competent
person.Ifthevalvedischargesatanytime,switchtheboileroff
andisolateitfromtheelectricalsupply.Contactyourinstallation/
servicecompany.
Cleaning
WARNING:Thisappliancecontainsmetalparts(components)
and care should be taken when handling and cleaning with
particular regard to edges of sheet metal parts to avoid any
possibility of personal injury.
Theboilercasingcanbecleanedwithadampcloth,followedby
a dry cloth to polish.
Do not use abrasive or solvent cleaners.
Maintenance and Servicing
To ensure the continued efficient and safe operation of the
applianceitisrecommendedthatitischeckedandservicedas
necessaryatregularintervalsbutingeneralonceayearshould
be enough, refer to guarantee registration on the inside front
cover of this literature.
If this appliance is installed in a rented property 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
personin accordance with the rulesin force in thecountries of
destination.
To obtain service, please call your installer or Glow-worm
Service using the telephone number on the inside front cover
of this literature.
Please be advised that the ‘Benchmark’ logbook should be
completed by the engineer on completion of commissioning
and servicing.
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
benchmark Logbook. You can check your installer is CORGI
registered by calling CORGI direct on: 01256 372300.
Spare Parts
REMEMBER,Whenreplacingapartonthisappliance,useonly
sparepartsthatyou can be assured conform to the safetyand
performance specification that we require. Do not use
reconditionedorcopypartsthathavenotbeenclearlyauthorised
by Hepworth Heating Ltd.
If a part is required contact Glow-worm Service using the
telephone number on the inside front cover of this booklet.
Pleasequote thenameof theappliance,this infomationwillbe
on the name badge on the front of the appliance.
If in doubt seek advice from the local gas company or Glow-
worm Service using the telephone number on the inside front
cover of this booklet.
Appliance Safety Devices
Maintenance and Servicing

74000123944-2
Controls and lighting
18
1144411445
1. Lighting the boiler:
Make sure that:
• The boiler is connected to the electrical
supply.
• The gas service cock is open.
Switch ON (I)
The running lamp will illuminate green.
2. Stop the boiler:
• Switch to OFF (0) the electrical supply is
OFF.
3. Domestic hot water temperature
adjustment:
• Press button once, is displayed and the
current temperature setting flashes.
•Press -or +tosetatemperaturebetween38°cto65°c.
• The display will default to normal after 5 seconds if no
buttons are pressed.
11525
Central heating adjustment
The temperature of the water in the central heating circuit can
be set between, approx. 38OC and 87OC.
It is supplied, factory set to 38OC - 73OC
Diagram 2
1 - OFF/ON switch
2 - Display
3 - Programing buttons
4 - Running lamp illuminated green when boiler
is ON (flashing red when fault indicated)
4
1
3
2Timed central heating and
instantaneous domestic hot water
Central heating and
domestic hot water
Domestic hot water only
Central heating only
Long absence / Holiday mode
and Appliance frost protection
11524
Domestic hot water
The temperature can be adjusted from approx. 38°C up to
65°C.

8
4000123944-2
Controls and lighting
4. Central heating temperature adjustment:
• Press button twice, is displayed and the
current temperature setting flashes.
•Press -or +tosetatemperaturebetween38°cto87°c.
• The display will default to normal after 5 seconds if no
buttons are pressed.
5. Heating Mode select:
• Press button three times, is displayed
and will flash along side the current mode setting.
• Press -or +to set as required.
• The display will default to normal after 5 seconds if no
buttons are pressed.
6. Long absence / Holiday mode:
• This mode protects the boiler against frost
7. If a fault occurs:
•The green running light willchangeto a red flashing light
andthedisplaywill flashtheletter‘F’withthetypeoffault.
•Reset the boiler: SwitchtheboilerOFF ( 0 ),waitforfive
seconds.Switchtheboiler ON (I ),theboilerisreset.If the
faultcontinuescallyourInstallation/Servicingcompanyor
Glow-worm Service using the telephone number on the
inside front cover of this literature.
(Ignition fault shown)
8. Installation filling:
• If the boiler loses water: The green running light will
changetoared flashing light and the display will flash the
letter ‘F’ with the low system water pressure fault and the
current system pressure.
• Fill the system by the filling device at the bottom of the
boiler until the pressure gauge reads 1.0 bar.
• Warning: Take care not to overfill the boiler. At a
pressure of 2.5 bar or above the high system water
pressure fault will be displayed. The pressure must be
reducedto1.0barbyopeningthedrainvalve,seediagram
1. If the fault continues call your Installation/Servicing
company or Glow-worm Service using the telephone
number on the inside front cover of this literature.
11526
11527
11528
11529

94000123944-2
Programmer instructions for use
Setting the time.
Make sure there is an electrical supply to the boiler and the
boiler is switched ON ( I ).
Press button four times, is displayed and the time
will flash, press -or +to set the correct time (24hr clock).
Setting the day.
Press button five times, is displayed and the
currentdaysettingwillflash,press-or+tosetthecorrectday.
1=MON, 2=TUE, 3=WED, 4=THU, 5=FRI, 6=SAT, 7=SUN
Setting the programmer.
Press button six times, is displayed.
press "+" and , and the will be
displayed along with 0 to 24 hour ON / OFF settings and 1 to 7
days of the week.
SetON/OFFtimesat30min intervalsforeach day1to7ofthe
week.
A flashing square is displayed below the current day of the
week selected, Press -or +to select the day 1 to 7 to be set.
Press to set ON / OFF times, and are
displayed,a flashing square will nowbedisplayed below the 0
along the top of the display along with the corresponding time
00:00OFF to the right of the display, this indicates that 00:00 to
00:30is settoOFF,tosetthistoON press+,or toset
to OFF press -, continue setting the ON / OFF times
for the remainder of that day / 24hr period in 30min intervals.
Press , and isdisplayed,press+toselect
the next day or -to select the previous day to be set, continue
setting the remaining days as required.
Thedisplaywilldefaulttonormalafter60secondsifnobuttons
are pressed.
115301153611537
1153811539

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4000123944-2
The 30ci plus is delivered in two separate
packages:
•Theboilerincludingfixingjigcompletewith
isolating valves and fittings.
• The flue system. Diagram 1.1
Net lift weight (boiler only) 41 kg
Gross lift weight (boiler and packaging) 47 kg
1 Technical Data
11542a
365 232
798
450
Heat input (max) NET Q 32,6 kW
111,231 BTU/H
Heat input (min) NET Q 12,5 kW
42,650 BTU/H
Heat output (max) NET P 29,6 kW
100,995 BTU/H
Heat output (min) NET P 10,3 kW
35,144 BTU/H
Efficiency - Sedbuk D 79,6%
Maximum heating temperature 87°C
Expansion vessel effective capacity 8 litres
Expansion vessel charge pressure 0,5 bar
Maximum system capacity at 75°C 156 litres
Safety valve, maximum service pressure 3 bar
Heating
Heat input (max) NET Q 32,6 kW
111,231 BTU/H
Heat input (min) NET Q 12,5 kW
42,650 BTU/H
Heat output (max) NET P 29,6 kW
100,995 BTU/H
Heat output (min) NET P 10,3 kW
34,155 BTU/H
Maximum hot water temperature 65 °C
Minimum hot water temperature 38 °C
Specific flow rate (for 35°C temp rise) 12,1 litres/min.
Threshold flow rate 1,7 litres/min.
Maximum supply pressure 10 bar
Minimum supply pressure 0,5 bar
Hotwater
Electrical supply 230 V ~ 50Hz
Electrical rating 122 W fused at 3A
Level of protection IPX4D
Fuse rating 1,25mA
Electrical
Products outlet diameter 60 mm
Fresh air inlet diameter 100 mm
Combustion products values CO (40 ppm)
CO2 (7,6%)
NOx (81ppm)
Combustion
Ø Burner injector 1,2 mm
Inlet pressure 20 mbar
Maxi. Burner pressure 13,3 mbar
Mini. Burner pressure 2,15 mbar
Gas rate maximum 3,45 m3/h
Natural Gas (G20)
Ø Burner injector 0,73 mm
Inlet pressure 29 mbar
Maxi. Burner pressure 25,5 mbar
Mini. Burner pressure 4,7 mbar
Gas rate maximum 2,53 kg/h
Butane Gas (G30)
Ø Burner injector 0,73 mm
Inlet pressure 29 mbar
Maxi. Burner pressure 32,5 mbar
Mini. Burner pressure 4,7 mbar
Gas rate maximum 2,53 kg/h
Propane Gas (G31)
30ci plus

11 4000123944-2
3 Heating System Design
•The 30ciplus isforusewithsealedcentralheatingsystems.
•Heating surfaces may consistof radiators, convectors orfan
assisted convectors.
•The safety valvesareanintegralpart of theboilerandcannot
be adjusted.
• The circulation pump is integral with the boiler.
• Pipe sectional areas shall be determined in accordance with
normal practices, using the output/pressure curve
(diagram 3.1). The distribution system shall be calculated in
accordancewiththeoutputrequirementsoftheactualsystem,
notthemaximumoutputoftheboiler.However,provisionshall
be made to ensure sufficient flow so that the temperature
difference between the flow and return pipes be less than or
equal to 20°C. The minimum flow is shown in Table 1.
The system can be fitted with a lockable balancing valve if
necessary in the main flow or return pipes shown as valve 'A'
in diagram 3.2.
• The piping system shall be routed so as to avoid any air
pockets and facilitate permanent venting of the installation.
Bleed fittings must be provided at every high point of the
system and on all radiators.
• The total volume of water permitted for the heating system
depends, amongst other things, on the static head in the cold
condition.Theexpansionvesselontheboilerispressurisedat
0.5 bar and allows a maximum system volume of 156 litres for
an average temperature of 75°C and a maximum service
pressure of 3 bar. This pressure setting can be modified at
commissioning stage if the static head differs. An additional
expansion vessel can be fitted to the system if required, see
diagram 3.2.
•Provisionshallbemadeforadrainvalveatthelowestpointof
the system.
•Wherethermostaticradiatorvalvesarefitted,notallradiators
must be fitted with this type of valve, and in particular, where
a room thermostat is installed.
•Inthecaseofanexistinginstallation,itisESSENTIALthatthe
system is thoroughly flushed prior to installing the new boiler,
UsingaproprietaryproductsuchasFernoxorSentinel. Contact
theproduct manufacturers forspecificdetails.
2 General Information
IMPORTANTNOTICE.
Where no British Standards exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
Refer to Manual Handling Operations, 1992 regulations.
Theinstallationofthisboilermustbecarriedoutbyacompetent
person in accordance with the rules in force in the countries of
destination.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
2.1 Sheet Metal Parts
WARNING: When installing the appliance, care should be
taken to avoid any possibility of personal injury when handling
sheet metal parts.
2.2 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 discribed in the following regulations:
Manufacturer’s instructions, supplied.
The Gas Safety (Installation and Use) Regulations.
The appropriate Building Regulations, either The Building
Regulations,The Building Regulations (Scotland), Thebuilding
Regulations (Nothern Ireland).
The Water Fittings Regulations or Water Bylaws in Scotland.
The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).
The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
InI.E the installationmustbe carried outbya competent person
and installed in accordance with the current edition of I.S. 813
"Domestic Gas Installations", the current Building Regulations
and reference should be made to the current ETCI rules for
electrical installation.
In GB the following Codes of Practice apply:
BS4814,BS5440Part1and2,BS5449,BS5546Part1,BS6700,
BS6798, BS6891 and BS7074 Part 1 and 2, BS7478, BS7593,
BS7671.
In IE: I.S.813, BS5546, BS5449, BS7074, BS7593.
Manufacturer’s notes must not be taken as overriding statutory
requirements.
BSI 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 Hepworth Heating Ltd.
Any alteration that is not approved by Hepworth Heating Ltd.,
couldinvalidatethewarrantyandcouldalsoinfringethecurrent
issue of the Statutory Requirements.
2.3 Gas Supply
The gas installation must be in accordance with the relevant
standards.
In GB this is BS 6891.
In IE this is the current edition of I.S.813 "Domestic gas
installation".
The supply from the governed meter must be of adequate size
toprovideasteadyinlet working pressure of 20mbar (8in wg) at
the boiler.
ImportantNotice
If your boiler has been converted to use L.P.G. Propane the
following note applies:
Propane cylinders are under pressure and should never be
stored or used indoors residentially.
They should only be kept outside.
Under no circumstances should L.P.G. Propane cylinders be
fitted or stored in basement areas or boiler houses.
Oncompletion,testthe gas installation for soundness using the
pressuredropmethodand suitableleak detectionfluid,purgein
accordance with the above standard.

12
4000123944-2
•CoppertubingorplasticHep20maybeusedforthedomestic
hot water system. Unecessary pressure losses should be
avoided.
• Provision shall be made for a drain valve at the lowest points
of the system.
•Theflowrestrictormust be fitted limiting the flow through the
boiler to a maximum of 12 l/min.
•Theboilerwilloperatewithaminimumsupplypressureof0,5
bar, at reduced flow rate.
Bestoperatingcomfortwillbeobtainedfromasupplypressure
of 1 bar.
4.1 Hard Water Areas
In areas where the water is 'hard', more than 200mg/litre, it is
recommended that a proprietary scale reducer is fitted in the
cold water supply to the boiler.
4 Domestic Hot Water System Design
0
10
20
30
40
50
60
70
0 200 400 600 800 1000 1200 1400
Flow rate through heating system l/h
Available pressure (kPa) between heating supply and return
1
2
3
4
5
11357
(10 kPa = 1 m WG)
1
2
3
4
5
Bypass fully shut
Open 1/4 turn
Open 1/2 turn
Open 1 turn
Open 2 turns
Diagram 3.1
Diagram 3.2
10015
Flow
control valve Drain point
Bypass
valve
Domestic
water
Heating
circuit
Return
Additional
expansion
vessel
(if required)
Boiler
Hot
Cold supply
Filling device
Bypass
(If required)
*
*
'A'
3 Heating System Design
3.1 Bypass
•The boiler is fitted with an adjustable automatic bypass.
Ensure that under no circumstances does the flow rate drop
below the figure specified, see Table 1.
• A bypass is not required on the central heating circuit unless
the system controls could allow the boiler to operate when
there is no flow.
• Where a bypass has to be fitted, the bypass must be placed
at least 1.5 metres from the appliance, see diagram 3.2.
3.2 Filling the system
Afillingdeviceisfittedtotheboilertoinitiallyfillthesystemand
replace water lost during servicing, see the relevant parts of
diagram 2 controls and lighting and diagram 3.2.
TABLE 1. FLOW RATE
Model Minimumflow rate
30ciplus 21.26 litres per minute
This is equal to 20°C differential at maximum heat input

13 4000123944-2
9
8
6
7
4
5
3
11
12 14
13
10
17
20 19
18
16 15
23
22
21 24
12
AB EDC
27
26
25
1 - Fan.
2 - Air pressure switch.
3 - Heat exchanger.
4 - Overheat thermostat.
5 - Combustion chamber.
6 - Expansion vessel.
7 - Flame sense electrode.
8 - Burner.
9 - Ignition electrode.
10 - Pump.
11 - Heating thermistor.
12 - Ignition unit.
13 - By-pass.
Diagram 5.1
11560
A - Heating flow
B - Domestic hot water outlet
C - Gas
D - Cold water inlet
E - Heating return
5 Boiler Schematic
14 - Gas valve.
15 - Loss of water sensor.
16 - Domestic heat exchanger
17 - 3 way valve
18 - Domestic water flow sensor
19 - Filter cold water inlet
20 - Filling system
21 - Discharge safety valve (3bar)
22 - Drain valve
23 - Heating filter
24 - Domestic safety valve 10 bar
25 - Micro accumulator vessel thermistor
26 - Micro accumulator vessel
27 - Heating element
FITTED TO
REAR OF
APPLIANCE

14
4000123944-2
6.1 Boiler Location
The recommended clearances are shown in diagram 6.1.
Note: The boiler must be mounted on a flat wall which is
sufficientlyrobusttotakeitsweightwhenfull.Ifindoubt,expert
advice should be obtained.
The minimum acceptable spacings from the terminal to
obstructions and ventilation openings are shown in diagram
6.2. For Ireland the minimum distances for the flue terminal
positionning must be those detailed in I.S.813 "Domestic Gas
Installations".
The boiler must be installed so that the terminal is exposed to
the external air.
6 Boiler Location, Flue and Ventilation
Diagram 6.1
11651a
*Note: It is permissible to install the boiler with smaller
clearances than those quoted PROVIDING that
consideration is given for Servicing/Repairs.
20mm
*
5mm
20mm
*
5mm
300mm
600mm
*
450mm
25mm
above
elbow
300mm
*
50mm
above boiler
(rear flue only)

15 4000123944-2
6 Boiler Location, Flue and Ventilation
Diagram 6.2
MINIMUM SITING DIMENSIONS FOR THE
POSITIONING OF FLUE TERMINALS MM
HORIZONTAL FLUES
A DIRECTLY BELOW, ABOVE OR
HORIZONTALLY TO AN OPENING, AIR BRICK,
OPENING WINDOWS, AIR VENT, OR ANY
OTHER VENTILATION OPENING 300
B BELOW GUTTER, DRAIN/SOIL PIPE 75
C BELOW EAVES 200
D BELOW A BALCONY OR CAR PORT 200
E FROM VERTICAL DRAIN PIPES AND
SOIL PIPES 150
F FROM INTERNAL/EXTERNAL CORNERS
OR TO A BOUNDARY ALONGSIDE THE
TERMINAL 300
G ABOVE ADJACENT GROUND OR
BALCONY LEVEL 300
H FROM SURFACE OR A BOUNDARY
FACING THE TERMINAL 600
I FACING TERMINALS 1200
J FROM OPENING (DOOR/WINDOW)
IN CAR PORT INTO DWELLING 1200
K VERTICAL FROM A TERMINAL 1500
L HORIZONTALLY FROM A TERMINAL 300
VERTICAL FLUES
M FROM ADJACENT WALL TO FLUE 300
N FROM ANOTHER TERMINAL 600
P FROM ADJACENT OPENING WINDOW 1000
Q ABOVE ROOF LEVEL 300
11508
Diagram 6.3
6.2 Terminal guard, see diagram 6.3.
Aterminalguardisrequiredifpersonscouldcomeintocontact
with the terminal or the terminal could be subject to damage.
Ifa terminal guard isrequired, it must bepositioned to provide
aminimumof50mmclearancefromanypartoftheterminaland
to be central over the terminal.
A suitable terminal guard type K3 can be supplied by:
Tower flue components Ltd.
Morley road
Tonbridge
Kent
TN9 1RA
6.3 Flue options
There are various flue systems to choose from as follows:
Horizontal telescopic rear flue pack.
Horizontaltelescopic top flue pack.
Horizontal top flue pack.
Horizontal extended flue pack.
Vertical flue pack.
Twin flue pack.
Extensions, 90°and 45°bends.
For detailed information refer to flue options guide. This is
available from your nearest stockist.
6.4 Cupboard or compartment ventilation
Theboiler can be fitted in acupboardor compartment without
the need for permanent ventilation.

16
4000123944-2
7 Fixing Jig
Diagram 7.1
11940a
22mm
22mm
15mm
15mm
22mm
V
W
W
WW
Z
Z
ZZ
X
X
X
YY
Y
A
B
C
D
E
Cold water
inlet restrictor
FIXING JIG
Inclusive Isolating
Valves
Wall template
APPLIANCE
HANGING
BRACKET
The fixing jig is supplied within the boiler pack and is made up as follows :
A - Heating flow isolating valve.
B - Domestic hot water outlet.
C - Gas service cock.
D - Cold water inlet isolating valve.
E - Heating return isolating valve.
Documentation Pack, inclusive
- Literature (not illustrated)
- Benchmark Book (not illustrated)
- Guarantee Registration form (not illustrated)
- Rewards Club leaflet (not Illustrated)
- Wiring Diagram (not illustrated)
- Flue restrictor (not illustrated)
Bag containing :
- 1 x 15mm green fibre washer (shown as "v" in diagram)
- Cold Water Inlet Restrictor
- 5 x 22mm fibre washers (shown as "w" in diagram)
Fittings Pack, inclusive
- Wall template
- Discharge Safety valve connection incl. Knurled nut and O ring seal
15mm compression fitting
- Discharge Safety Valve Instruction sheet
- 230V External connection instruction sheet
- Filling loop extension knob
- 230V External controls connection plug
Bag containing :
- 3 x 22mm Installation connection pipes
- 2 x 15mm Installation connection pipes
Bag containing :
- 4 x 22mm boiler connection pipes
- 1 x 15mm boiler connection pipe
Bag containing :
- 4 x 15mm fibre washers (shown as "x" in diagram)
- 4 x 22mm fibre washers - large bore (shown as "y" in diagram)
- 5 x 22mm fibre washers - small bore (shown as "z" in diagram)
Sealing Washers :
30ciplus Description
V 1 (1) 15 mm Gas valve Connection only*
W 4 (5) 22 mm - smal bore
X 3 (4) 15 mm
Y 3 (4) 22 mm - large bore
Z 4 (5) 22 mm - smal bore
The quantity shown in bracket ( ) denotes the number supplied
* It is essential that this green sealing washer is only fitted to the gas valve connection in the position shown in the Fixing Jig diagram

17 4000123944-2
8 Boiler Preparation and System Connections
8.1 Cutting the flue hole
•Removethewalltemplate,followtheinstructionsgivenonthe
walltemplate.
•Position thewalltemplate,taking due regardofthe minimum
clearances for the selected flue application, see diagram 8.1.
• Horizontal Rear hole cutting
• Mark position of Rear flue outlet hole from template, then
remove template, before cutting, for use, later. The core drill
used should be 115 mm diameter.
• Top Outlet Side / Rear hole cutting
• Mark the centre line for the hole on the wall. Extend the
horizontal centre line to the side wall if required and mark the
vertical centre line of the hole as shown in diagram 8.1.
• Making allowance for the slope of the flue, cut hole in wall,
preferably using a core drill. For installations with internal and
externalaccessusea105mmdiametercoredrill. Forinstallations
with only internal access use a 125mm diameter core drill.
IMPORTANT NOTE: When cutting the flue hole and when
extendingthe fluecentrelineto asidewall, remember thatthe
flue system must have a fall of about 35mm per metre of flue
downward towards the terminal. There MUST never be a
downwardinclinetowards the boiler.
Note: Iftheapplianceisnottobefittedforsometime,coverthe
hole in the wall.
8.2 Rear Flue - Internal Installation Only
Referto"HorizontalTelescopicRearFlue"instructions,section
10 and prepare the flue system. Insert the flue system into the
holesuchthatitwillnotinterferewiththeappliancewhenlifting
intoposition.
8.3 Fixing jig, refer to diagram 7.1
•IMPORTANTNOTE:Ensurethatthefixingjigisfittedtoaflat
and true wall area for correct alignment with the boiler. If this
cannotbeachieveditis acceptable to pack out the fixing jig to
obtainthecorrect alignment.
SideFlue- Checkthehorizontalcentrelineandrepositionthe
template if necessary.
Rear Flue - Reposition the wall template over the hole in wall.
•Mark the securing position holes.
• Check that the fixing jig is level.
•Drill,plugandsecurethejigtothewall, usingsuitablescrews
(not supplied) for the wall type and capable of supporting the
total weight of the appliance.
8.4 Water connection
IMPORTANTNOTE:Donotsubjecttheisolatingvalvestoheat
fromblowlamp,whenmaking connection.
Connectthesystempipeworktothefixingjig connectionpipes
andthefixingjigisolatingvalves, observingthecorrectflowand
return as shown in diagram 8.1.
8.5 Gas connection
Gas Safety (Installation and use) Regulations
Inyourinterestsandthatofgassafety,itisthelawthatALLgas
appliancesareinstalledandservicedbyacompetentpersonin
accordance with the above regulations.
•Thewholeofthe gas installation, including the meter, should
be inpected, tested for soundness and purged in accordance
withthecurrentissueofBS6891andinIEthecurrenteditionof
I.S.813 "Domestic Gas Installations".
20mm*
min.
145
63
80 min
C.H. flow
Gas supply
Cold water in
D.H.W. hot out
C.H. return
22 mm.
CENTRAL HEATING
15 mm.
DOMESTICWATER
22mm.
GAS SUPPLY
KEY
Diagram 8.1
NOTE
MINIMUM
CLEARANCES
refer diagram 6.1
11942
*
REAR
FLUE
OUTLET
232
REAR TOP FLUE
OUTLET
*

18
4000123944-2
9 Boiler Installation
11581
9.1 Sheet metal parts
WARNING: Wheninstallingorservicingthisboiler,careshould
betakenwhenhandlingtheedgesofsheetmetalpartstoavoid
the possibility of personal injury.
9.2 Installing the boiler
IMPORTANT NOTE: The system must be thoroughly flushed
usingaproprietycleanserfrom FernoxorSentineltoeliminate
any foreign matter and contamination e.g. metal filings, solder
particles, oil, grease etc.
Solvent products could cause damage to the system.
• Remove front panel, unscrew and remove the two retaining
screwsfromthebottomofthefrontpanel. Removefrontpanel
by lifting up and forward.
• Remove the self adhesive wiring diagram label from the
documentenvelope. Fit the selfadhesivewiringdiagramlabel
totheinsideofthefrontpanel,put frontpanelinasafeplaceto
avoid damaging it.
(Horizontal Telescopic Rear Flue Only)
Fitthefluespigotand gasket , refer to diagram 9.3, supplied in
thefluepacktotherearoftheappliance,havingfirstmovedand
secured the blanking plate to the top outlet.
• Ensure the plastic plugs are removed from water and gas
pipes. NOTE: There will be some spillage of water.
• Fit the cold water inlet restrictor (supplied in the document
envelope)intocoldwaterinletisolatingvalve,seediagram7.1.
Important Note. With regards to the manual handling
operations,1992 regulations, the following operation exceeds
the recommended weight for one man lift.
•Lifttheboilerupandengageboileronto thehanging bracket,
refer to diagram 7.1.
• Fit the boiler jig connection pipes and washers between the
boiler and isolating valves, see diagram 7.1.
DISCHARGE
SAFETY VALVE
PIPE
KNURLED
UNION NUT
finger tighten only
Diagram 9.2
10088
FILLING LOOP
EXTENSION
FILLING
DEVICE
Diagram 9.1
Diagram 9.3
SPIGOT
SECURING
SCREW (4)

19 4000123944-2
Diagram 9.4
11581
HEATING SAFETY
VALVE (3 bar RED)
DISCHARGE PIPE
9.3 Heating safety valve (3 bar RED) and
domestic safety valve (10 bar BLUE)
discharge, refer to diagrams 9.4.
Two short discharge pipes and washers are supplied in the
fittings pack, fit these to the heating safety valve 3 bar and the
domestic water safety valve 10 bar. The discharge must be
extendedusingpipenot less than 15mm. od. to discharge ina
visiblepositionoutsidethebuilding,facingdownwardpreferably
over a drain.
IMPORTANT NOTE: To facilitate servicing of the appliance,
the discharge pipe MUST ONLY be extended using the
compressionfittingssupplied.
The pipes must have a continuous fall and be routed to a
position so that any discharge of water, possibly boiling or
steam,cannotcreateanydangertopersons,damagetoproperty
or external electrical components and wiring. Tighten all pipe
connectionjoints.
9.4 Filling loop extension
The filling loop extension knob is supplied in the discharge
safetyvalvepipeconnectionpack.Fittothefillingdeviceon/off
knob, this is a push fit, see diagram 9.2.
9 Boiler Installation
DOMESTIC SAFETY
VALVE(10 bar BLUE)
11588
DISCHARGE PIPE
Fingertightentheknurledunionnut

20
4000123944-2
10 Horizontal Telescopic Rear Flue Installation
Pho 087
Diagram 10.3
10.1 Horizontal Telescopic Rear flue -
kit No. A2018000, refer to diagram 10.1
Suitable for installations that require a flue length "L" 193 -
510mm.Forfluelengthslessthan328mmtheductwillneedto
be cut, see diagram 10.2.
To makeaneatfinishtotheflueoutlet,afluecollarkit,partNo.
900850, with instructions, is available, see diagram 10.3.
Flue and Air Duct preparation
Extend the telescopic flue to the required length, making sure
that the minimum overlap is no less than 25mm, see diagram
10.2,andthattheflueterminalprojects15mmminimumbeyond
the wall face.
Carefully drill though air duct pilot hole and secure with self
tappingscrewprovidedin fittingspack.
Seal the joint with the tape provided.
Fittheselfadhesivefoamsealprovidedinthefluepackaround
theairductatapositionsuchthatitwillbeinthewall,shownin
diagram 10.2.
Make sure that the ductings do not slope down towards the
boiler.
Pushthe flueassemblyintoand through theholesuch that itis
withinthewall,anddoesnotstickoutintotheroom. Donotpush
theflueassemblytoofarintotheholeasithastobepulledback
into the boiler and secured.
Now continue with Fixing Jig and system connections, see
section8,thencompletetheflueinstallationasdescribedinthe
following paragraphs 10.2 to 10.6.
10.2 Sealed chamber cover
•Unscrewandremovethetworetainingscrewsfromthesealed
chamber cover, see diagram 10.4
• Lift cover up and off pins on top of boiler.
12060
The flue kit No. A2018000 comprises:
- Telescopic flue assembly ..................................... A
- Sensing tube cap (fitted) ......................................B
- Gasket.....................................................................C
- Spigot ...................................................................... D
- Tape ......................................................................... E
- Foam seal ................................................................ F
- Screws 6 off ............................................................G
- Restrictor flue hood outlet ................................... H
Diagram 10.1
Horizontal Rear Telescopic flue kit
A
B
C
E
D
F
H
G
Diagram 10.2
"L" FLUE LENGTH =
"Y" WALL THICKNESS + 133mm
12007
NOTE:Ifitisnecessarytocutthe"fluelength",makesure
that the overlaps are as follows:- air duct = 25mm
flue duct = 50mm
FOAM SEAL
Diagram 10.4
9533