Glowworm Economy Plus 60F User guide

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All replacement parts
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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 First Year Guarantee.
In the center pages are to be found your Guarantee Registration Card, which we recommend you complete and
return as soon as possible.
If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer
Service number 01773 828100.
Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:
Guarantee Registration
Fanned Flue Boilers
This is a Cat I2H Appliance
BS 6332
BS 5258
Reference in these instructions to British Standards and Statutory
Regulations/Requirements apply only to the United Kingdom.
For Ireland the rules in force must be used.
The instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee Registration
Card. 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.
Tobeleftwiththeuser
3558
❏
✔
❏
✔
❏
✔
Instructions for Use
Installation and Servicing
G.C. No. 41 319 63
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0181 380 2555
60F

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Important Information
Introduction 3
Lighting the Boiler 4
General Data 1 5
Water Systems 2 7
Boiler Location 3 10
Flue 4 11
Preparation 5 13
Water Connection 6 18
Flue Assembly Installation 7 18
Gas Connection 8 20
Electrical Connection 9 20
Commissioning 10 21
Completion 11 24
Servicing 12 25
Fault Finding 13 26
Replacement Parts 14 31
Spare Parts 15 35
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
SERVICING
INSTRUCTIONS
Testing and Certification
Thisboileristestedandcertificatedforsafetyandperformance. Itisthereforeimportantthatnoalterationismadetotheboiler,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, see Section 1.4.
CE Mark
This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is deemed
tomeettherequirementsofDirective92/42/EEContheefficiencyrequirementsfornewhotwaterboilersfiredwithliquidorgaseous
fuels.
Type test for purposes of Regulation 5 certified by: Notified body 0086.
Product/productioncertifiedby: Notified body 0086.
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 the Member States relating to electromagnetic compatibility.
INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.
Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to
health.
CERAMIC FIBRE/INSULATION PADS, GLASSYARN.
These can cause irritation to skin, eyes and the respiratory tract. 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. 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 of the eyes or severe
irritation to the skin seek medical attention.
THERMOSTATS
These contain very small amounts of xylene in the sealed phial and capillary. If broken, under normal circumstances the fluid does
notcauseaproblem,but in caseofskincontact,washwithcold water. Ifswalloweddrinkplentyofwaterand seek medical attention.
CUT-OFF DEVICES
Thesecontainactivatedcharcoalandaverysmallamountofchlorodifluormethanein the sealed phial and capillary. If broken, under
normal circumstances the fluid does not cause a problem. If there is irritation to the eyes or skin then seek medical attention.

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Introduction
Pleasereadtheseinstructionsandfollowthemcarefullyforthe
safe and economical use of your boiler.
The Economy Plus “F” Range are boilers designed to provide
central heating and indirect domestic hot water from a fully
pumped system with a fully indirect cylinder.
Important Notice
This boiler is for use only on natural gas G20 gas.
Gas Safety (Installation and Use) Regulations.
In your interest and that of gas 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.
Gas Leak or Fault
If a gas leak or fault exists or is suspected, the BOILER MUST
BE TURNED OFF, including the electrical supply and MUST
NOT BE USED UNTIL THE FAULT HAS BEEN PUT RIGHT.
Advice/helpshouldbe obtainedfromyourinstallation/servicing
company or the local gas undertaking.
Maintenance/Servicing
To ensure the continued efficient and safe operation of the
boiler it is recommended that it is checked and serviced as
necessary at regular intervals. The frequency of servicing will
depend upon the particular installation conditions and usage,
but in general once a year should be enough.
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.
It is the Law that any servicing must be carried out by a
competent person.
To obtain service, please call your installer or Heatcall (Glow-
worm’s own service organisation) using the telephone number
given on the case tray.
Boiler Clearances
If fixtures are positioned close to the boiler space must be left
asshownindiagram1. Enoughspacemustalsobeleftinfront
of the boiler to allow for servicing.
Boilers Installed in a Compartment or
Cupboard
If the boiler is installed in a cupboard or compartment do not
obstruct any ventilation openings.
Do not use the cupboard or compartment for storage.
Regularly make sure that the air vent openings are clear of
obstructions.
Cleaning
WARNING. Thisappliancecontainsmetalparts(components)
and care should be taken when handling and cleaning, with
particular regard to edges.
Clean the casing occasionally by wiping it over with a damp
soapy cloth or dry polishing duster.
Do not use an abrasive cleaner.
Boiler Electrical Supply
WARNING. The boiler must be earthed.
The boiler must only be connected to a 240V~50Hz supply,
protected by a 3A fuse.
All wiring must be in accordance with the current issue of
BS7671.
The colours of three core flexible cable are:
Brown - live, blue - neutral, green and yellow - earth.
As the markings on your plug may not correspond with these
colours, continue as follows,
The wire coloured blue must be connected to the terminal
marked “N” or “Black”.
The wire coloured brown must be connected to the terminal
marked “L” or “Red”.
The wire coloured green and yellow must be connected to the
plug terminal marked “E” or “Green” or the earth symbol " " .
Electrical Supply Failure
Failure of the electrical supply will cause the burner to go out.
Should this happen, operation of the appliance will normally
resume after the electrical supply is restored.
Iftheburnerdoesnotrelightafteranelectricalsupplyfailurethe
overheatdevicemayneedresetting,refertodiagram2,remove
the controls tray and press the reset button.
Ifthecutoffoccursagain,turntheapplianceoffandcontactyour
installation/servicing company.
Instructions for Use
PERMANENT
SURFACE
DD
B
A
3540
150
EE
3540
CLEARANCES Diagram 1

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Data/Serial Number Label
TheGCnumberoftheappliancecanbefoundontheDatalabel,
positioned at the top right of the inner cover.
The model name and serial number are located on the control
box cover, visible when the controls tray is removed.
To Turn the Boiler On
Sealed Water Systems.
CAUTION.Asealedwatersystemmustbefilledandpressurised
by a competent person.
Only light the boiler when you are sure that the system and
boiler have been filled and pressurised.
Thepressuregaugeshouldshowatleast 0.7bar,anythingless
thanthisfigurecouldindicatealeakandyouMUSTcontactyour
installation/servicing company.
If there is any doubt about the boiler being full of water consult
your installation/servicing company.
All Systems
Turn the electrical supply on to the boiler and check that any
remote controls are set to your requirements (refer to
manufacturer’s instructions for these items).
Remove the controls tray by withdrawing it forwards.
Turn the boiler thermostat knob clockwise to any position
between “MIN” and “MAX”, see diagram 2. The maximum
setting is about 82oC (180oF).
The boiler lighting operation is now automatic as follows:
The fan operates, followed by an ignition spark until the pilot is
lit. Whenthepilotisalighttheignitionswitchesoffandthemain
burner lights. The flames can be seen through the viewing
window.
Themainburnerwillremainalightuntilswitchedoffbytheboiler
thermostat or other remote control.
If the boiler thermostat is turned Off, by hand, wait at least 30
seconds before turning on again.
Whentheboilergoesoff,boththepilotandmainburnergo out.
The automatic lighting sequence will operate again when heat
is required.
Refit the controls tray.
To Turn the Boiler Off
For short periods, turn thermostat control knob anti-clockwise
until“O”isagainstthesettingpoint. To relightthemainburner,
turnthethermostatknobclockwisetoanysettingbetween ”MIN”
and “MAX”.
For longer periods, turn the thermostat control knob anti-
clockwise until “O” is against the setting point.
Switch off the electrical supply to the boiler.
To relight follow the sequence given above.
Protection Against Freezing
If the boiler is to be out of use for any long period of time during
severeweatherconditionswerecommendthatthewholeofthe
system, including the boiler, be drained off to avoid the risk of
freezingup. Makesurethat,iffitted,theimmersionheaterinthe
cylinder is switched off.
If you have a sealed water system contact your installation/
servicing company as draining, refilling and pressurising must
be carried out by a competent person.
Diagram 2
BOILER CONTROLS
3560
VIEWING
WINDOW
CONTROLS TRAY
BOILER THERMOSTAT CONTROL KNOB
OVERHEAT
CUT-OFF
RESET
BUTTON
SERIAL No.
SETTING
POINT
Instructions for Use

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102
63
360
600
45
86
60
42
300
WATER CONNECTIONS FLUE
TERMINAL
DETAIL
GAS CONNECTIONS
==
122
*
55
from boiler top.
58mm from inner case top.
*
122
1 General
Diagram 1.1GENERAL ARRANGEMENT
6472
MODEL
LIFTING
WEIGHT
Rc 1/2(
1/2in. BSPT)
GAS
CONNECTION
WATER
CONNECTION 28mm copper,
flow at right, return at left
65W, internal fuse F1A.
ELECTRICITY
RATING
WATER
CONTENT
TOTAL
WEIGHT
240V~50Hz Fused 3A
DATA LABEL On the inner case front
TABLE 1. ECONOMY PLUS DATA
ELECTRICITY
SUPPLY
0.8Litre
(1.4pt)
33.0Kg
(72.8lb)
26.5Kg
(58.4lb)
60F
1.1 Important Notice
This boiler is for use only on G20 gas.
The boiler is delivered in one pack.
Wherever possible, all materials, appliances and components
to be used shall comply with the requirements of applicable
British Standards.
Where no British Standard exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
This boiler must have fully pumped circuits, but is suitable for
use with open vented or sealed systems.
This boiler is not suitable for outdoor locations.
1.2 Sheet Metal Parts
WARNING. When installing or servicing the boiler care should
betakenwhenhandlingsheetmetalpartstoavoidanypossibility
of personal injury.
1.3 Statutory Requirements
TheinstallationoftheboilerMUSTbecarriedoutbyacompetent
person in accordance with the relevant requirements of the
current issue of:
Manufacturer’s instructions, supplied.
TheGasSafety(InstallationandUse)Regulations,TheBuilding
Regulations, The Building Standards (Scotland) Regulations
(applicable in Scotland), local Water Company Bye-laws, The
Health and Safety at Work Act, Control of Substances Harmful
toHealth, TheElectricityatWorkRegulationsandanyapplicable
local regulations.

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RANGE RATING
NOMINAL Btu/h
HEAT
INPUT(GROSS) kW
NOMINAL Btu/h
HEAT
OUTPUT kW
BURNER m bar
SETTING
PRESSURE in.w.g
APPROX m
3
h
GAS
RATE ft
3
h
min medium max
1.8 1.9 2.1
63.0 68.5 74.0
50,000 55,000 60,000
14.65 16.12 17.58
63,290 68,750 74,070
18.55 20.15 21.71
TABLE 2. MODEL 60F
9.4 11.2 13.0
3.8 4.5 5.2
Detailedrecommendationsarecontainedinthecurrentissueof
thefollowingBritishStandardsandCodesofPractice,BS4814,
BS5440 Part 1 and 2, BS5449, BS5546, BS6700, BS6798,
BS6891, BS7074 Part 1 and 2. BS7478, BS7593, BS7671.
Manufacturer’snotesmust not be taken as overridingstatutory
requirements.
1.4 B.S.I. Certification
The boiler is certificated to the current issue of BS6332 Part 1,
invoking the current issue of BS5258 Part 1 for performance
andsafety. It is,therefore,importantthat 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.,
couldinvalidatetheB.S.I.Certificationoftheboiler,thewarranty
and could also infringe the current issue of the Statutory
Requirements.
1.5 General Data
The data label is positioned on the inner case visible when the
front panel is removed.
The serial number plate is positioned on the control box cover,
visible when the controls tray is removed.
TheGeneralArrangementdiagram1.1andallotherdimensions
are given in millimetres.
General Data refer Table 1
1.6 Range Rating
The boiler is range rated and is factory set to maximum, it may
be adjusted to suit individual system requirements, refer to
Table 2.
1.7 Gas Supply
The gas installation must be in accordance with the current
issue of BS6891.
The supply from the governed meter must be of adequate size
toprovideasteadyinletworkingpressureof20mbar(8inwg)at
the boiler.
Oncompletion,testthegasinstallationforsoundnessusingthe
pressure drop method and leak detection fluid, purge in
accordance with the current issue of BS6891.
1.8 Electrical Supply
WARNING. This boiler must be earthed.
Allsystemcomponentsshallbeoftheapprovedtypeandwiring
shall comply with and be connected in accordance with the
requirementsofthecurrentissueofBS7671andanyapplicable
local regulations.
Connection of the boiler and system controls to the mains
supply must be through a common isolator and must be fused
3Amaximum. Thismethodofconnectionshouldbe,preferably,
by a fused double pole isolating switch, provided it has a
minimumcontactseparationof3mmonbothpoles.Thisshould
bereadily accessible and preferably adjacent to the appliance.
Itshouldsupplytheapplianceonly 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.
Wiring to the boiler must be PVC insulated type to the current
issueofBS6500Table16,notlessthan0.75mm2(24/0.20mm).
1.9 Heating System Controls
The heating system should have installed: a programmer and
room thermostat controlling the boiler.
Thermostaticradiatorvalvesmaybeinstalled in additiontothe
room thermostat.
Note: For further information, see The Building Regulations
1991-Conservationoffuelandpower,1995edition-Appendix
G, table 4b.
1 General

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2 Water System
Diagram 2.2OPEN VENTED SYSTEM
Open (vented) system.
Recommended
relationship between
pump, cold feed and
vent.
22 mm (MIN) VENT
FEED AND
EXPANSION
CISTERN
15mm (MINIMUM)
COLD FEED
15mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE
450mm
MIN.
HEIGHT
1150mm
MIN.
150
mm
MIN.
BOILER
PUMP
150mm
MAX
FLOW
RET.
ALTERNATIVE
PREFERRED
RET.
CYLINDER
FLOW
HEATING
0005M
Notes: Open Vented and Sealed Systems
See chart for pressure drop of the boiler diagram 2.1.
2.1 Draining Tap
The boiler is provided with a draining tap at the lower left hand
side of the heat exchanger, to be used for draining the heat
exchanger.
A draining tap must be provided at the lowest points of the
systemwhichwillallowtheentiresystemandhotwatercylinder
to be drained.
Draining taps shall be to the current issue of BS2879.
2.2 Safety Valve
A safety valve need not be fitted to an open vented system.
2.3 Circulating Pump
The pump should be fitted in the flow pipe from the boiler and
have isolating valves each side, integral if possible.
A variable duty pump should be set to give a temperature
difference of 110C (20oF) between the flow and return with the
thermostat set at “MAX” which is about 82oC (180oF), to give a
design flow rate as shown in Table 3.
High resistance microbore systems may require a higher duty
pump.
2.4 Bypass
A BYPASS MUST BE FITTED, see diagram 2.2 for a suitable
position.
Theflowratethroughtheboilermustnotbeallowedtofallbelow
that given in Table 4.
Where the water system can allow the boiler and pump to
operateonbypassonly,abypassmustbeplacedatleast1.5m
away from the boiler.
2.5 Inhibitor
Attention is drawn to the current issue of BS5449 and BS7593
on the use of inhibitors in central heating systems.
If an inhibitor is to be used, contact a manufacturer for their
recommendations as to the best product to use.
Ifusinginanexistingsystemtakespecialcaretodraintheentire
system, including the radiators, then thoroughly flushing out
before fitting the boiler whether or not adding inhibitor.
TABLE 4.
MINIMUM FLOW RATE at MAX OUTPUT
MODEL 60F 16.4L/min 3.6gal/min
TABLE 3.
DESIGN FLOW RATE at MAX OUTPUT
MODEL 60F 23.0L/min 5.1gal/min
PRESSURE LOSS OF BOILER
1.5
1.0
0.5
0
50
40
30
20
0
0510 15 20 25 30
Flow rate (litres/minute)
Water pressure loss
(metres head of water)
Water pressure loss
(inches head of water)
10
60
0123456
Flow rate (gallons/minute)
35 40
70
78
2.0
0164M
Diagram 2.1
22mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE
2.6 Open (Vented) Water System
For an open (vented) system the boiler must be supplied from
an unrestricted water supply taken from a feed and expansion
cistern situated at a maximum height of 27.5metres (90ft)
above the boiler.
The cold feed supply must be 15mm minimum size.
The vent must rise continuously and be unrestricted.
Itis important that the relative positions of the pump, cold feed
and open vent are as shown in diagram 2.2.

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2 Water System
3 LITRES (0.66 gals)
MAKE-UP BOTTLE
(if required)
NON-RETURN
VALVE
AUTO
AIR
VENT
FLOW
DRAIN
COCK BOILER
SAFETY
VALVE
(Make-up
alternatives) EXPANSION
VESSEL
PRESSURE
GAUGE
CIRCULATING
PUMP
FILLING POINT
AIR
RELEASE
POINT
HEATING CIRCUIT
22mm (min)
BY-PASS WITH
LOCKSHIELD
VALVE
RETURN
5814
Diagram 2.3SEALED WATER SYSTEM DIAGRAMMATIC LAYOUT
2.7 Domestic Hot Water Cylinder
The hot water cylinder must be of the double feed fully indirect
type. Not the single feed self priming type.
2.8 Sealed Water Systems
Theinstallationmustcomplywiththeappropriaterequirements
ofthecurrentissueofBS5449,BS6759,BS6798,BS4814and
BS7074 Part 1 and 2.
See diagram 2.3 for a suggested layout.
2.9 Safety Valve
A safety valve must be fitted to a sealed water system.
It shall be preset, nonadjustable with a lift pressure of 3bar,
incorporatingseating of a resilient material,a test device and a
connection for drain.
The drain from the safety valve must be routed clear of any
electrical fittings and positioned so that any discharge can be
seen.
2.10 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 2.3, unless laid
down differently by the manufacturer.
The expansion vessel volume depends on the total water
systemvolumeandtheinitialsystemdesignpressure. For any
system an accurate calculation of vessel size is given in the
current issue of BS7074 Part 1.
Example: For an initial system design pressure of 0.7bar, the
minimum total vessel volume required is 0.063xTotal System
volume.
Note: A higher initial design pressure requires a larger volume
expansion vessel.
Guidance on vessel sizing is also given in the current issue of
BS5449 and BS7074 Part 1.
Thechargepressuremustnotbelessthanthestaticheadofthe
system, that is, the height of the highest point of the system
above the expansion vessel.
The water content of the boiler is given in the Data Table 1.

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M
ETHOD 1
SUPPLY STOP
VALVE
SUPPLY
PIPE
HOSE
UNIONS SERVICING
VALVE
TEMPORARY
HOSE
HEATING
SYSTEM
COMBINED
CHECK VALVE
AND VACUUM
BREAKER
0051M
Diagram 2.4
METHOD 3 Cistern filling method
METHOD 2 Mains topping up method
METHOD 1 Mains topping up method
FILLING A SEALED SYSTEM
2 Water System
METHOD 2
HEATING
SYSTEM
TEMPORARY
HOSE
HOSE
UNIONS SERVICING
VALVE
SUPPLY
PIPE
SUPPLY STOP
VALVE
DOUBLE CHECK
VALVE ASSEMBLY
HEATING
SYSTEM
SERVICING
VALVE
SUPPLY
STOP VALVE
SUPPLY
PIPE
HOSE
UNIONS DOUBLE CHECK
VALVE ASSEMBLY
OVERFLOW
CISTERN
PRESSURE
REDUCING
VALVE
2.11 Pressure Gauge
A pressure gauge with a set pointer and covering at least 0 to
4bar (0 to 60lb in2) shall be fitted permanently to the system in
a position where it can be seen when filling the system.
2.12 Domestic Hot Water Cylinder
SINGLEFEEDINDIRECTCYLINDERSARENOTSUITABLE.
The hot water cylinder must be of the indirect coil type. It must
be suitable for working at a gauge pressure of 0.35bar above
the safety valve setting.
2.13 Water Makeup
Provision should be made for replacing water loss from the
system using a make up bottle or filling loop mounted in a
position higher than 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 for make up can be made using a filling
loop.
2.14 Filling a Sealed System
Provisionforfillingthesystematlowlevelmustbemade. Three
methodsareshownindiagram2.4. Theremustbenopermanent
connection to the mains water supply, even through a non-
return valve.

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C
DD
E
E
APERMANENT
SURFACE
B
MINIMUM CLEARANCES
A
B
C
D
E
500
78
*
10
5
*
*
To a permanent surface
SIDE FLUE - 220mm
REAR FLUE - 120mm
WHERE EXTERNAL ACCESS TO
THE FLUE IS NOT PRACTICAL THEN
CLEARANCE OPPOSITE THE EXIT
MUST BE ADEQUATE TO PERMIT
INSTALLATION OF THE FLUE ASSEMBLY
0073
M
Diagram 3.1
CLEARANCES
TABLE 5. COMPARTMENT AIR VENTS
VENTILATION
REQUIREMENTS
cm2in2cm2in2
VENTILATION
FROM ROOM
OR SPACE
HIGH LEVEL LOW LEVEL
VENT AREA VENT AREA
195 30 195 30
98 15 98 15
VENTILATION
FROM
OUTSIDE
3 Boiler Location
3.1 Boiler Location
The boiler may be installed in any room although particular
attention is drawn to the requirements of the current issue of
BS7671 with respect to the installation of a boiler in a room
containing a bath or shower. Any electrical switch or boiler
control using mains electricity should be so situated that it
cannot be touched by a person using the bath or shower.
The electrical provisions of the Building Standards (Scotland)
are applicable to such installations in Scotland.
The boiler must be mounted on a flat wall which is sufficiently
robust to take its total weight, see Data Table 1.
3.2 Boiler Clearances
The boiler must be positioned so that at least the minimum
operational and servicing clearances are as shown in diagram
3.2.
Additional clearance may be required around the boiler for
installation purposes, dependant upon site conditions.
3.3 Timber Frame Buildings
Iftheboileristo be installedinatimberframebuilding,it should
be fitted in accordance with the British Gas Publication “Guide
forGasInstallationinTimberFramedHousing”referenceDM2.
If in doubt, seek advice from the local gas undertaking or
Hepworth Heating Ltd.
3.4 Room Ventilation
Theboilerisroomsealed,sowheninstalledinaroomor space
a permanent air vent is not required.
3.5 Cupboard or Compartment Ventilation
Where the boiler is fitted in a cupboard or compartment,
permanenthighandlowlevelventilationmustbeprovided. The
ventilation areas required are given in Table 5.
Wheretheinstallationoftheboilerwillbeinanunusuallocation,
special procedures are necessary, refer to the current issue of
BS6798 for guidance.
Make sure that the cupboard or compartment air vents are
positioned to be clear of obstructions at all times.
A compartment used to enclose the boiler must be designed
and constructed specifically for this purpose.
Anexistingcupboard or compartment modified for thepurpose
may be used. Refer to the current issue of BS6798 for
guidance.
The doorway opening should be of sufficient size to allow for
easy removal of the boiler.

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Diagram 4.1
A
A
FGEA
G
G
G
B,C B,C
FF
K
K
K
C
G
LL
UNDER CAR PORT etc.
H,I
JD
F
K
4 Flue
4.1 Flue
The flue must be installed in accordance with the current issue
of BS5440 Part 1.
The air and flue duct connect to the top of the boiler using an
elbow which can be positioned to the sides or rear.
The standard flue is able to provide the duct lengths ranges
shown in diagram 4.2 rear flue and 4.3 side flue.
If a longer flue duct is required, do not extend the ductings.
A 1,2 and 3m flue system and terminal can be supplied. This is
able to provide the duct length range as shown in diagram 4.2
for a rear flue, diagram 4.3 for a side flue.
4.2 Terminal Position
The minimum acceptable spacings from the terminal to
obstructionsand ventilation openings are as shown in diagram
4.1.
The boiler must be installed so that the terminal is exposed to
the external air.
It is important that the position of the terminal allows the free
passage of air across it at all times.
Car ports or similar extensions of a roof only, or a roof and one
wallrequirespecialconsiderationwithrespecttoanyopenings,
doors, vents or windows under the roof. Care is required to
protect the roof if it is made of plastic sheeting.
If the car port comprises of a roof and two or more walls, seek
advice from the local gas company before installing the boiler.
Where the terminal is fitted within 600mm (24in) below plastic
guttering an aluminium shield 1500mm (5ft) long should be
fittedtotheundersideandimmediatelybeneaththegutteringor
eaves.
Wheretheterminalisfittedwithin450mm(18in)beloweavesor
painted guttering an aluminium shield 750mm (2ft6in) long
should be fitted to the underside and immediately beneath the
guttering or eaves.
4.3 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
aminimumof50mmclearancefromanypartoftheterminaland
be central over the terminal, see diagram 4.1.
A suitable terminal guard can be obtained from:
Tower Flue Components Ltd.,
Morley Road,
Tonbridge,
Kent.
TN9 1RA
their reference K3.
A DIRECTLY BELOW AN OPENABLE mm
WINDOW, 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 75
F FROM INTERNAL OR EXTERNAL 300
CORNERS
G ABOVE ADJECENT GROUND OR
BALCONY LEVEL 300
H FROM A SURFACE 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
MINUMUM SITING DIMENSIONS FOR
FANNED FLUE TERMINALS
POSITION MINIMUM
SPACING
0161M
2816

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Diagram 4.4FLUE COLLAR KIT
4 Flue
3774
4.4 Flue Collar Kit
A flue collar kit, part No.443286 (with instructions) is available.
This can be used to cover the flue, as shown in diagram 4.4
Pleasenote,theuseofthiscollarwillmeanthat thefluelengths
will need to be altered, full instructions are given in the kit.
Rear Flue Lengths
Side Flue Lengths
S
R
6890
6891
1m FLUE PACK 75 mm to 961 mm
2m FLUE PACK 75 mm to 1961mm
3m FLUE PACK 75 mm to 2941mm
STD FLUE PACK 75 mm to 469 mm
Diagram 4.2
Diagram 4.3
1m FLUE PACK 310 mm to 1080 mm
2m FLUE PACK 310 mm to 2080 mm
3m FLUE PACK 310 mm to 3060 mm
STD FLUE PACK 310 mm to 585 mm

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Diagram 5.3
WALL TEMPLATE
(Side and Rear)
SIDE FLUE
3286
5.2 Flue Preparation
All flue assemblies are designed for internal installation, given
that there is sufficient clearances opposite to the flue exit for
installation of the flue and the fixing of side panels.
If there are insufficient clearances the flues can be installed
externally from outside.
For a wall thickness up to 300mm, provided there is sufficient
space available, the flue can be fully installed from the inside.
For a wall thickness of over 300mm the external cut hole will
need to be made good from the outside.
5.3 Rear and Side Flue Application
Select the boiler location and flue application, with due regard
to the terminal position:
Takethetemplatefromtheboilerpackandtemporarilyposition
it on the wall, making sure that the minimum clearances are
maintained, see diagram 3.1.
Note:Thetemplate has“Fixture’s”alignmentmarks foreaseof
installation.
For rear flue, mark the position of the flue as diagram 5.3.
For side flue, extend the centre line horizontally left or right to
the corner of the adjacent surface where the flue is required to
exit to outside. Mark the position of the centre of the flue, as
diagram 5.3
REAR FLUE
115mm
MINIMUM
HOLE
122mm
5 Preparation
FITTINGS PACK
INSTALATION
LITERATURE
USER
LITERATURE
BOILER
CARTON
TEMPLATE
Diagram 5.1
BOILER PACK CONTENTS
4796
5.1 Unpacking
Openthecartonandcheckthe itemssuppliedagainsttheliston
the flap, see diagram 5.1.
Place the boiler on one side, until required.

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SECURING
SCREW (2)
MOUNTING
PLATE
5mm
TEMPLATE
TOP BOILER
MOUNTING
HOLES
MOUNTING PLATE
FIXING POINT
5.5
ø
3
/ 16 ø PLUG
No. 10x
1
/ 2 in.
5.5
ø
3
/ 16 ø PLUG
0064M
Diagram 5.4
BOILER MOUNTING and
PLATE FIXING POINTS
5 Preparation
0064M
5.4 Flue Hole Cutting
Having marked out the flue centre cut a hole for the flue using,
preferably, a 115mm minimum core drill.
Note: If required, an optional Wall Liner Kit, part No.900862, is
available, complete with fixing instructions.
5.5 Wall Mounting Bracket
Reposition the template, ensuring dimensional alignment with
the flue hole.
Mark the boiler securing screws and mounting plate position,
see diagram 5.4.
Drill holes and plug, to suit No10x50mm woodscrews, fit the
screwsallowingsufficientclearancetoacceptthekeyholefixing
brackets.
Secure the boiler mounting plate to the wall with No.10x50
woodscrews and plugs, see diagram 5.4.
5.6 Flue Duct (Standard or Long)
Mark the duct to the length required (this length allows for
expansion), see diagram 5.5 for Rear flue and diagram 5.6 for
Side flue, then cut square and remove any burrs.
Diagram 5.5FLUE DUCT (REAR FLUE)
*Increase dimension by 15mm if the
“Optional Flue Collar” is to be fitted.
FLUE DUCT
* Qplus 70mm
Q
6893

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Diagram 5.8
* S minus 47mm
(If flue collar is to be fitted overall
dimension increased by 15mm)
SIDE FLUE
AIR DUCT / TERMINAL
LONG FLUE
TERMINAL
STANDARD
FLUE
TERMINAL
* Splus 60mm
BOILER
CENTRE
LINE
s
6895
Diagram 5.6FLUE DUCT (SIDE FLUE)
Diagram 5.7
REAR FLUE
AIR DUCT / TERMINAL
*Increase dimension by 15mm if the
“Optional Flue Collar” is to be fitted.
* S minus 37mm
(If flue collar is to be fitted overall
dimension increased by 15mm)
5 Preparation
* SMinus 52mm
BOILER
CENTRE
LINE
LONG FLUE
TERMINAL
STANDARD FLUE
TERMINAL
* Qplus 60mm
Q
s
5.7 Air Duct/Terminal (Standard or Long)
Marktheductlength,seediagram5.7forRearflueanddiagram
5.8 for Side flue, then cut square and remove any burrs.
5.8 Air Duct/Terminal and Flue Duct Assembly
Locate the flue duct into the air duct/terminal, see diagram 5.9.
Fully locate the flue elbow into the air/terminal and flue duct
assembly as shown, ensuring correct alignment of the “Top”,
see diagram 5.10.
Mark the position of securing holes through the flue elbow
outlet, see diagram 5.10.
Drill two 3mm diameter holes, see diagram 5.10.
5.9 External Flue Installation
Remove the flue elbow from the air duct/terminal and flue duct
assembly.
Note: Donotinserttheflueassemblybutplaceononesideuntil
required.
Continue at “Boiler Preparation”
6892
6894

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Diagram 5.9
AIR DUCT /
TERMINAL ASSEMBLY
Diagram 5.10
FLUE ELBOW ASSEMBLY
5 Preparation
FLUE
DUCT
AIR DUCT / TERMINAL
ASSEMBLY
3mm
DRILL SIZE
SEAL WITH
TAPE SUPPLIED AIR DUCT/TERMINAL &
FLUE DUCT ASSEMBLY
FLUE ELBOW
ASSEMBLY
REAR FLUE
SECURING POINTS SIDE FLUE
SECURING POINTS
LHD/RHD
LHD
RHD
5.10 Internal Flue Installation
Ifaccess to the outside wall is not practical, the flue system can
be installed from inside. Use of the optional wall liner kit
recommended.
Secure the flue elbow to the air duct/terminal with the two self
tapping screws supplied in the fittings pack, see diagram 5.10.
Place the sealing tape from the fittings pack around the flue
elbow as diagram 5.10.
Place the flue assembly to one side until required.
Continue at “Boiler Preparation”.
5.11 Wall Liner
If a wall liner is used, fit self adhesive seal as follows:
Forwallthicknessesupto300mmfittheselfadhesivesealtothe
air duct, see diagram 5.11, make sure the joint is on top.
For wall thicknesses over 300mm see diagram 5.12..
When installed the seal will be within the wall.
3293
3294
Diagram 5.11
FOAM SEAL
(Wall Thickness up to 300mm)
*Increase dimension by 15mm if the
“Optional Flue Collar” is to be fitted.
* 10mm
FOAM SEAL
Q
6896

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Diagram 5.14
BOILER MOUNTING
MOUNTING
PLATE
3550
CONTROL
TRAY FRONT COVER
CASE REMOVAL Diagram 5.13
4810
KEYHOLE SLOT
MOUNTING BRACKET
Diagram 5.12
FOAM SEAL
(Wall Thickness over 300mm)
5 Preparation
Qminus 25mm
Q
FOAM SEAL
5.12 Boiler Preparation
Removethecontrolstrayandoutercaseandplaceononeside
until required, see diagram 5.13.
Discardpackingpiecefrombetweenfrontcoverandinnercase
Note: If convenient, a connection can be made to the gas
service cock at this time.
Lift the boiler into position above the boiler mounting plate,
lowering the boiler into position at the same time locating the
key hole slots of the boiler on to the securing screws, when
located secure the screws, see diagram 5.14.
6897

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Diagram 6.1
WATER CONNECTION
6 Water Connections
UNION NUT
OLIVE
WATER
CONNECTION
COPPER
TUBING
RETURN FLOW
Makethewaterconnectiontotheheatingsystem,seediagram
6.1.
The boiler has compression connections, with nuts and olives
supplied loose in the fittings pack, to accept 28mm outside
diameter copper tubing to BS2871.
The right hand connection is the flow from the boiler.
3551
7.1 Flue Assembly Preparation.
Removetheinnercasebyreleasingthesecuringscrews,place
on one side until required, see diagram 7.1.
Removetheviolet(orblue)andredelectricalconnectionsfrom
the fan see diagram 7.2.
Breaktheairpressureswitchtube(s)connection(s),seediagram
7.2.
Slacken but do not remove the flue hood securing angle wing
nuts, see diagram 7.2.
Removethe fan and mounting plateassembly by removing the
two securing screws, see diagram 7.2.
7.2 External Flue Installation
Offer the air duct/terminal flue duct assembly into and through
the hole and wall.
Secure the flue elbow to the air duct/terminal with the two self
tapping screws, supplied in the fittings pack, into the holes
previously drilled.
Place the sealing tape from the fittings pack around the flue
elbow as diagram 5.11.
Continue at “Flue/Boiler Connection”.
Diagram 7.1
INNER CASE
DATA LABEL
PILOT
VIEWING
WINDOW
SERIAL
NO PLATE
INNER
CASE
3552
SECURING
SCREW (4)
7 Flue Assembly Installation

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Diagram 7.3INTERNAL FLUE ASSEMBLY
Diagram 7.4
FLUE ASSEMBLY /
BOILER CONNECTION
Diagram 7.5
FLUE ELBOW SPIGOT
GASKET
WASHER (3) SECURING
SCREW (3)
FLUE ELBOW
SPIGOT
FAN RETAINING
BRACKET
693435543344
Diagram 7.2
FLUE PREPARATION
7 Flue Assembly Installation
FAN ELECTRICAL
CONNECTIONS AIR PRESSURE
SWITCH TUBES
RED
CLEAR
SECURING
SCREW (4)
FAN / MOUNTING
PLATE ASSY.
SECURING
SCREW (2)
COMBUSTION
CHAMBER
FRONT PANEL FLUE HOOD
WING NUTS
3303
7.3 Internal Flue Installation
Push the flue assembly into and through the wall, see diagram
7.3.
7.4 Flue/Boiler Connection
Secure the flue elbow and gasket to the boiler with the three
screws and washers, previously removed, see diagram 7.4.
Replace the fan and mounting plate assembly ensuring
engagementofthe fan into the flue elbowandthe fan retaining
bracket, see diagram 7.5 and secure with the two screws
previously removed.
Connecttheairpressureswitchtubesandelectricalconnections.
Makegoodaroundtheflueandflueterminalandfittheterminal
guard.

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8 Gas Connection
Diagram 8.1
GAS VALVE
(cover removed for clarity)
GAS SERVICE
COCK (shown on )
Make the gas connection, refer to diagram 8.1.
9 Electrical Connection
Diagram 9.1
CABLE RETAINING CLIPS
SELF ADHESIVE
BACKED CABLE
CLIPS
9.1 Electrical Connection
WARNING. This boiler must be earthed.
Take the two plastic cable retaining clips, from the loose items
pack,peeloff the backing paper and positionthemas shown in
diagram 9.1.
Removethecontrolboxbysupportingitandremovingthefixing
screw,lowerslightlyandpull forward todisengage,supportthe
box on the lip bracket at the front, see diagram 9.2.
Take care not to damage any internal wiring and capillaries.
Using heat resistant (85oC) PVC insulated cable of at least
0.75mm2 (24/0.2mm) to the current issue of BS6500 Table 16,
and of a suitable length, thread the cable through the cable
clampsecureintotheplasticclipsandconnecttotheappropriate
terminals, see diagram 9.3 and 13.5.
Standardcoloursare,brown-live,blue-neutralandGreenand
Yellow - earth.
The mains cable outer insulation must not be cut back external
to the cable clamp, see diagram 9.3.
Whenmakingconnections,makesurethattheearth conductor
is made of greater length than the current carrying conductors,
so that if the cable is strained the earth conductor would be the
last to become disconnected.
CAUTION. It is essential that the polarity is correct.
9.2 Pump Connection
The pump must be connected directly to the control box, as
shownin diagram 9.3 and13.5 threading the cablethrough the
cable clamp in the side of the control box.
9.3 External Controls
Remove the red link between 9 and SL in the control box when
using any external controls.
Always make sure that all cables are secured and clear of hot
surfaces.
3301
3555
9.3 Testing - Electrical
Checks to ensure electrical safety should be carried out by a
competent person.
After installation of the system, preliminary electrical system
checks as below should be carried out:
1. Test insulation resistance to earth of mains cables.
2. Test the earth continuity and short circuit of all
cables.
3. Test the polarity of the mains.