Glowworm FUELSAVER 65 User guide

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COSHH
220678B.11.96
To be left with the user
Installation & Servicing Instructions
4746
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
One Contact Total Service
Customer Services:
Tel: [phone]
Fax: [phone]
Fanned Flue Sealed System Boiler
65 GC No. 41 319 21 80 GC No. 41 319 18
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.

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1 General
OVERALL DIMENSIONS
3130
108
450
161
783
*
174
321
101
783
346 66
2.5
25
SAFETY
VALVE
DISCHARGE
All dimensions in millimetres
KEY:
22mm COMPRESSION
CENTRAL HEATING
Rc
1
/
2
(
1
/
2
in. BSPT)
GAS CONNECTION
STD FLUE TERMINAL = 63
LONG FLUE TERMINAL = 61
*
*
Diagram 1.1
The instructions consist of two parts, Installation and
Servicing Instructions and Instructions for Use, 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.
1.1 Important Notices
This boiler is for use only on G20 gas.
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 is not suitable for use out of doors.
THIS BOILER IS FOR USE ONLY IN A SEALED
WATER SYSTEM.
1.2 Sheet Metal Parts
WARNING. When installing or servicing the boiler
care should be taken when handling sheet metal parts to
avoid any possibility of personal injury.
1.3 Statutory Requirements
The installation of the boiler MUST be carried out by a
competent person in accordance with the relevant
requirements of the current issue of:
Manufacturer’s instructions, supplied.
The Gas Safety (Installation and Use) Regulations,
The Building Regulations, The Building Standards
(Scotland) Regulations (applicable in Scotland) Local
Water Company Bye-laws, The Health and Safety at
Work Act, Control of Substances Hazardous to Health,
The Electricity at Work Regulations and any applicable
local regulations.
Detailed recommendations are contained in the current
issue of the following British Standards and Codes of
Practice,
BS4814, BS5440 Part 1 and 2, BS5449, BS5546, BS6700,
BS6798, BS6891, BS7074 Part 1 and 2, BS7478, BS7593,
BS7671.
Manufacturer’s instructions must not be taken as
overriding statutory requirements.
1.4 BSI Certification
The boiler is certificated to the current issue of BS6332
Part 1, invoking the current issue of BS5258 Part 1 for
performance and safety. It is, therefore, 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., could invalidate the BSI Certification of the boiler,
the warranty and could also infringe the current issue of
the Statutory Requirements.

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1 General
CE Mark
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 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.
1.5 Range Rating
The boiler is range rated and is factory preset to maximum,
but may be adjusted to suit individual system requirements,
refer to Range Rating Table 2.
1.6 Equipment
The boiler is supplied with an integral expansion vessel,
circulating pump, safety valve, pressure gauge, low water
pressure warning light, automatic bypass valve, gas cock
and valved water connections (with drain points).
Data Label
The data label is positioned on the inner case cover.
Appliance Data refer to Table 1.
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 to provide a steady inlet working pressure of 20mbar
(8in wg) at the boiler.
On completion, test the gas installation fro the soundness
using the 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.
All system components and wiring shall be of the approved
type and comply with and be connected in accordance with
the requirements of current issue of BS7671 and any
applicable local regulations.
Connection of the boiler and system controls to the mains
supply must be through a common isolator and must be
fused 3A maximum. The method of connection should be,
preferably, by a fused double pole isolating switch,
provided it has a minimum contact separation of 3mm on
both poles. This switch should be readily accessible 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 used provided that they are not used in a room
containing a bath or shower.
Wiring to the boiler must be PVC insulated cable at least
0.75mm2(24/0.20mm) to the current issue of BS6500
Table 16.
MODEL
TABLE 1
LIFTING
WEIGHT
Rc 1/2(
1
/
2
in. BSPT)
GAS
CONNECTION
WATER
CONNECTION 22mm copper,
return at right, flow at left
150W, internal fuse F1A.
ELECTRICITY
RATING
WATER
CONTENT
TOTAL
WEIGHT
240V~50Hz fused 3A
ELECTRICITY
SUPPLY
DATA LABEL On the inner case front
65 80
0.8 litre 0.8 litre
(0.176 gal) (0.176 gal)
54.22kg 54.22kg
(119.53lb) (119.53lb)
39.72kg 39.72kg
(87.57lb) (87.57lb)
RANGE RATING
NOMINAL Btu/h
HEAT
INPUT kW
NOMINAL Btu/h
HEAT
OUTPUT kW
BURNER m bar
SETTING
PRESSURE in.w.g
APPROX m
3
h
GAS
RATE ft
3
h
TABLE 2. Complheat 80
82,600 91,200 99,000
24.2 26.7 29.0
65,000 72,500 80,000
19.1 21.2 23.4
9.3 11.7 13.9
3.7 4.7 5.6
2.3 2.5 2.7
81.2 88.3 95.3
min mid max
RANGE RATING
NOMINAL Btu/h
HEAT
INPUT kW
NOMINAL Btu/h
HEAT
OUTPUT kW
BURNER m bar
SETTING
PRESSURE in.w.g
APPROX m
3
h
GAS
RATE ft
3
h
TABLE 2. Complheat 65
68,320 74,400 80,340
20.0 21.8 23.5
55,000 60,000 65,000
16.1 17.6 19.1
9.9 12.0 14.1
4.0 4.8 5.7
1.9 2.1 2.2
67.1 74.2 77.7
min mid max
INJECTOR
SIZE 3.7mm 4.3mm

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2 Water System
Diagram 2.2
WATER SYSTEM
DIAGRAMATIC LAYOUT
2.1 General Notes
The installation of the boiler must comply with the
requirements of the current issue of BS6798.
2.2 Safety Valve
The safety valve, preset at 3bar, is an integral part of the
boiler and cannot be adjusted.
2.3 Pressure gauge
A pressure gauge is incorporated into the boiler to
indicate the system pressure.
2.4 Circulating Pump
The circulating pump is integral with the boiler.
The remaining conveying capacity of the pump is shown
in diagram 2.1.
2.5 Expansion Vessel
The boiler has an integral expansion vessel with a
capacity of 12 litres (2.64 gallons), with a charge
pressure of 0.75bar.
The maximum heating system water content using the
fitted expansion vessel ranges from 176 litres with a cold
fill pressure of 0.7bar, to 145 litres with a cold fill
pressure of 1.05bar. If, due to a high static head, the
cold fill pressure is higher, then the expansion vessel
pre-fill pressure must be increased and the maximum
system volume decreased, see the current issue of
BS7074 Part 1.
Further information can be obtained from the British Gas
Publication “British Gas Specification for Domestic Wet
Central Heating Systems” and the current issue of
BS4814, BS5449 and BS7074 Part 1 and 2.
2.6 Flow Rate
A valve must be incorporated in the main flow or return
of the system, valve “A” shown in the flow diagram 2.2.
This valve must be lockable and be positioned so that
inadvertent closure or unauthorised interference is not
possible. The design differential is 11oC (20oF) with the
boiler thermostat set at “MAX” which is about 82oC
(180oF). The pump adjuster should always be left at
maximum (3).
2.7 Bypass
An automatic bypass valve is incorporated in the boiler
pipework it is preset and must not be adjusted.
Diagram 2.1
3131
3 LITRES
MAKE-UP
BOTTLE
(if required)
NON-RETURN
VALVE
AUTO
AIR
VENT
'A'
ADDITIONAL
EXPANSION
VESSEL
(if required)
DRAIN
COCK
BOILER
RETURN
FLOW CONTROL
VALVE
FILLING
POINT
HEATING CIRCUIT
REMAINING CONVEYING
CAPACITY OF PUMP
WATER FLOW RATE
AT 110C (200F) DIFFERENTIAL
UNIT 65 80
litre/min. 24.9 30.6
gal/min. 5.5 6.7
3131/C
12
10
8
6
4
2
0
3.0
2.4
1.8
1.2
0
0612 18 24 30 36
Flow rate (litres/minute)
Available pump head (Ft)
0.6
3.6
01.3 2.6 4.0 5.2 6.6 7.9
Flow rate (gallons/minute)
Available pump head (m)
Nominal flow rate
for 11
0
C differential
65 80
9.2
14 4.2
42

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2 Water Systems
Diagram 2.3
FILLING SEALED
WATER SYSTEMS
2.8 Water Make Up
Provision should be made for replacing water lost from
the system using a make up bottle mounted in a position
higher than the top point of the system, connected
through a non-return valve to the return side of the
heating circuit, see diagram 2.2.
Alternatively, provision for make up can be made using
a filling loop.
2.9 Filling Sealed Water Systems
Provision for filling the system at a low level must be
made.
Three methods of filling are shown in diagram 2.3.
There must be no permanent connection to the mains
water supply, even through a non-return valve.
2.10 Corrosion 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 in the system, contact a
manufacturer for their recommendations.
2.11 Existing Systems
When fitting the boiler into an existing system, special
care should be taken to drain the entire system, including
radiators, then thoroughly cleaning out before fitting the
boiler whether or not adding an inhibitor.
2.12 Draining Tap
A draining tap must be provided at the lowest points of
the system, which will allow the entire system to be
drained. An additional draining tap MUST be fitted
close to the boiler.
Draining taps must be to the current issue of BS2879.
The flow and return isolating valves on the boiler are
fitted with drain points for heat exchanger draining.
2.13 Domestic Hot Water System
General
The domestic hot water service must be in accordance
with the current issue of BS5546, refer also to the
current issue of BS6700.
2.14 Domestic Hot Water Cylinder
SINGLE FEED INDIRECT CYLINDERS ARE NOT
SUITABLE AND SHOULD NOT BE USED.
The domestic hot water cylinder must be of the indirect
coil type. It must be suitable for a working at a gauge
pressure of 0.35bar above the safety valve setting.
2.15 Domestic Hot Water System -
Unvented
Where a storage system will not have a vent to
atmosphere the installation must comply with Building
Regulations and local Water Company bye-laws, see
also the current issue of BS6700.
If fitting into an existing system the local authority
should be informed.
2819
METHOD 1
METHOD 2
METHOD 3
SUPPLY STOP
VALVE
SUPPLY
PIPE
HOSE
UNIONS SERVICING
VALVE
TEMPORARY
HOSE
HEATING
SYSTEM
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
COMBINED
CHECK VALVE
AND VACUUM
BREAKER
PRESSURE
REDUCING
VALVE

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3 Boiler Location
3.1 General
The boiler may be installed in any room although
particular attention is drawn to the requirements of the
current issue of the 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) Regulations are applicable to such
installations in Scotland.
The boiler must be mounted on a flat wall which is
sufficiently robust to take its complete weight, see Data
Table 1.
This boiler may be fitted to a wall made of combustible
material, see diagram 3.1.
3.2 Boiler Clearances
The boiler should be positioned so that at least the
minimum operational and servicing clearances are
provided, see diagram 3.1.
3.3 Timber Frame Buildings
If the boiler is to be installed in a timber frame building,
it should be fitted in accordance with the British Gas
Publication “Guide for Gas Installation in Timber
Framed Housing” reference DM2. If in doubt, seek
advice from the local gas undertaking or Hepworth
Heating Ltd.
3.4 Room Vent
The boiler is room sealed, so when installed in a room or
space, a permanent air vent is not required.
3.5 Cupboard or Compartment Vent
Where the boiler is fitted in a cupboard or compartment,
permanent high and low level ventilation must be
provided.
The vent areas required are given in Table 3.
Where the installation of the boiler will be in an unusual
location, 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.
An existing cupboard or compartment modified for the
purpose may be used, refer to the current issue of
BS6798 for guidance.
The doorway opening should be of sufficient size to
allow easy removal of the boiler.
MINIMUM CLEARANCES Diagram 3.1
MINIMUM CLEARANCES FROM WALLS, CEILING,
FLOOR, CUPBOARD, WORKTOPS AND
INFLAMMABLE MATERIALS
❋ WHERE EXTERNAL ACCESS TO
THE FLUE IS NOT PRACTICAL THEN
CLEARANCE MUST BE ADEQUATE TO
PERMIT INSTALLATION OF THE FLUE
3133
5
5
5*
150
5*
TABLE 3. COMPARTMENT AIR VENTS
VENTILATION
REQUIREMENTS HIGH LEVEL LOW LEVEL
VENT AREA VENT AREA
cm2in2cm2in2
VENTILATION
FROM
ROOM
OR SPACE
MODEL
VENTILATION
FROM
OUTSIDE
65
80
212 32 212 32
261 40 261 40
106 16 106 16
131 20 131 20
65
80
800*
186
5
5

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SIDE FLUE Diagram 4.2
REAR FLUE Diagram 4.1
The flue must be installed in accordance with the current
issue of BS5440 Part 1.
The air and flue ducting connect to the top of the boiler
using an elbow which can be positioned to the left or
right hand side or the rear.
The rear and side flue assemblies are designed for
internal installation, but if necessary, due to insufficient
clearances (boiler/flue terminal location) they can be
installed from the outside.
For a wall thickness up to 300mm the flue can be fully
installed from the inside.
For wall thickness of over 300mm the external cut hole
will need to be made good from the outside.
The standard flue will provide the flue length range as
shown in diagram 4.1 and 4.2.
If a longer flue is required, do not extend the ducting. A
1, 2 or 3metre flue system must be used and can be
supplied. This will provide the flue length range as
shown in diagram 4.1 and 4.2.
A "Flue Bend Kit" and "Vertical Flue Kit" can be
supplied.
4 Flue
STANDARD FLUE TERMINAL ILLUSTRATED
STANDARD FLUE TERMINAL ILLUSTRATED
3134
3135
Rear Flue Lengths
S='External wall face’to‘boiler mounting frame’
Side Flue Lengths
Flue. STD 80mm to 547mm
1m 80mm to 857mm
2m 80mm to 1857mm
3m 80mm to 2852mm
Flue. STD 75mm to 598mm
1m 75mm to 913mm
2m 75mm to 1913mm
3m 75mm to 2908mm
R= Wall Thickness
'R'
'S'

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4 Flue
4.1 Terminal Position
The minimum acceptable siting dimensions for the
terminal from obstructions, other terminals and
ventilation openings are shown in diagram 4.3.
The terminal must be exposed to the external air, the
position allowing free passage of air across it at all
times.
Car ports or similar extensions of a roof only, or a roof
and one wall, require special consideration with respect
to any openings, 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. If the terminal is fitted
within 600mm below plastic guttering and aluminium
shield 1500mm long should be fitted immediately
beneath the guttering or eaves. If the terminal is fitted
within 450mm below painted eaves or a painted gutter,
an aluminium shield 750mm long should be fitted
immediately beneath the guttering or eaves.
4.2 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 a minimum of 50mm clearance from any part of
the terminal and be central over the terminal.
A suitable guard as shown, reference type K3, can be
obtained from:
Tower Flue Components Ltd.,
Morley Road,
Tonbridge,
Kent.
TN9 1RA
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
2816
A DIRECTLY BELOW AN OPENABLE
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
CORNERS 300
G ABOVE ADJACENT 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
MINIMUM SITING DIMENSIONS
FOR FANNED FLUE
TERMINALS POSITION
0161M
Diagram 4.3

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5 Preparation
OUTER CASE Diagram 5.1
Diagram 5.3GAS SERVICE COCK / WATER ISOLATING VALVES
INNER CASE COVER Diagram 5.2
5.1 Unpacking
Remove the top carton from the boiler.
To remove the outer case, slide the information plate up
to access and remove the single securing screw, see
diagram 5.1, unhook the case at the top and lift it off.
Remove the cover of the inner case, secured with four
screws, see diagram 5.2.
Disconnect the gas service cock union and the front
unions of the isolation valves, see diagram 5.3.
Slacken but do not remove the retaining strap screws of
the gas service cock and the isolating valves.
3137
31383139
OUTER CASE SECURING SCREW
INFORMATION
PLATE
RETAINING
STRAP
GAS SERVICE
COCK UNION
RETAINING
STRAP RETAINING
STRAP
RETURN
WATER
ISOLATING
VALVE
UNION
INNER CASE
COVER
SECURING
SCREW (4)
FLOW
WATER
ISOLATING
VALVE
UNION

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5 Preparation
Diagram 5.4
SIDE FLUE Diagram 6.2 BOILER FIXING POINTS Diagram 6.1
BOILER
MOUNTING FRAME
6 Installing the Flue
Remove the two boiler securing screws, see diagram 5.4
then separate the boiler from the mounting frame, by
pulling the location studs/clips apart then unhook it at
the top.
3141
173 173
115 Dia. FLUE
CENTRE
LINES
CORNER
(LEFT FLUE)
CORNER
(RIGHT FLUE)
3142
3143
FLUE
TEMPLATE
BOILER
MOUNTING FRAME
FIXING POINTS
480
629
149
78 FLUE
CENTRE LINE
115 Diameter
Top of
Boiler
MINIMUM
CLEARANCE
300
BOILER
SECURING SCREW (2)
BOILER
MOUNTING FRAME LOCATION
STUD(S) and CLIP(S)
6.2 Marking
The boiler mounting frame is the same width as the
boiler but the flue connection sticks up above it. Place
the boiler mounting frame on the wall in the required
position, maintaining minimum clearances, see
diagram 3.1.
6.1 General
With due regard to boiler location, clearances and
having determined the flue application, length and
terminal position carry on as follows:

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6 Installing the Flue
WALL SLEEVE Diagram 6.3
Diagram 6.4
BOILER
MOUNTING FRAME
Make sure that the isolation valves are at the bottom
facing forward and that the frame top is horizontal, then
mark the four wall fixing points through the holes in the
two horizontal straps, do not drill the holes,
see diagram 6.4.
Position the flue template on the wall, the arrow points
on the centres of the two upper fixing points previously
marked, see diagram 6.1 which also gives dimensions.
For a rear flue, mark the rear flue position as required,
centre or diameter.
For a side flue, mark the horizontal flue centre line at the
sides of the template. Extend the flue centre line
horizontally left or right to the internal corner where the
flue is required to exit to the outside. Mark the position
of the circular hole, on the flue exit wall, using the
dimensions given in diagram 6.2.
From the flue position marks, check that the flue
terminal will be in a suitable position, see diagram 4.3.
6.3 Flue Hole Cutting
Cut a horizontal hole in the wall, making sure that there
is no downward slope towards the boiler position, using,
preferably, a core drill, to the diameter shown in diagram
6.1 and 6.2.
6.4 Wall Sleeve
Take the wall sleeve from the pack. If the wall thickness
“Q” is less than 300mm, cut the wall sleeve to the
required length, see diagram 6.3. If the wall thickness
“Q” is greater than 300mm the sleeve must be fitted
flush with the outside wall face.
Place the sleeve into the hole.
Make good around the wall sleeve at both internal and
external wall faces, through the wall sleeve if internal
access only is available.
For a wall thickness of over 300mm the external wall
face will need to be made good from the outside.
6.5 Boiler Mounting Frame - Fixing
Position the flue template over the flue hole and check
the position of the wall fixing points. Mark the position
of the fixing holes again, if required, see diagram 6.1.
Drill the four holes and insert wall plugs to suit
No10x50mm screws.
Secure the boiler mounting frame to the wall using
No10x50mm screws, see diagram 6.4.
Note: Remove the clear plastic protective film from the
sides of the boiler mounting frame.
3145
FIXING
POINTS
Q
3144
300mm
MAX.
LENGTH
WALL
SLEEVE
Q
BOILER MOUNTING
FRAME

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6 Installing the Flue
SIDE FLUE - FLUE DUCT Diagram 6.8
Diagram 6.7
SIDE FLUE - AIR DUCT /
TERMINAL ASSEMBLY
REAR FLUE - FLUE DUCT Diagram 6.6
Diagram 6.5
6.6 Flue Preparation
Rear Flue
Mark and cut the air duct terminal assembly, see diagram
6.5 and the flue duct, diagram 6.6 to the lengths required,
cutting square and removing any burrs.
Refer to diagram 6.9, mark through the holes in the flue
elbow assembly and drill the flue duct as shown.
Side Flue
Mark and cut the air duct terminal assembly, see diagram
6.7 and the flue duct, diagram 6.8 to the lengths required,
cutting square and removing any burrs.
Refer to diagram 6.9, mark through the holes in the flue
elbow assembly and drill the flue duct as shown.
6.7 Flue Assembly
Note. At this point if side or front access is restricted,
continue at “External Flue Assembly”.
Internal Flue Assembly
Locate the flue duct into the flue elbow assembly and
secure with the screws provided, see diagram 6.9.
Fully locate the flue elbow and flue duct assembly into
the air duct/terminal assembly as shown, making sure of
correct terminal alignment of the “TOP”,
see diagram 6.10.
Mark the position of the air duct terminal assembly
securing holes and drill two 3mm diameter holes through
the air duct/terminal assembly.
Secure the air duct/terminal assembly to the flue elbow
and flue duct assembly with the two self tapping screws
supplied in the loose items pack and then seal with the
tape provided.
3147
FLUE
DUCT
'R' + 107
'R'
3148
3149
'S' + 163
FLUE
DUCT
'S'
REAR FLUE - AIR DUCT /
TERMINAL ASSEMBLY
'R' + 92
STANDARD
FLUE
TERMINAL
'R'
AIR DUCT/
TERMINAL
ASSEMBLY
3146
STANDARD FLUE TERMINAL ILLUSTRATED
1M,2M,3M FLUE TERMINAL
'S' + 148
'S'
1M,2M,3M FLUE TERMINAL
AIR DUCT/
TERMINAL
ASSEMBLY
STANDARD
FLUE
TERMINAL
STANDARD FLUE TERMINAL ILLUSTRATED

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6 Installing the Flue
Diagram 6.10
FLUE ASSEMBLY
Fix the self adhesive seal to the air duct,
see diagram 6.11.
Place the flue assembly into the flue hole. Make sure
that the flue terminal is correctly positioned and sticking
out the correct distance from the outside wall face, see
diagram 6.11.
Note. The foam seal is a tight fit in the wall sleeve, so
either the wall sleeve will need to be rigidly fixed in the
wall, that is, the cement has fully set or it can be held
from the other side whilst inserting the flue assembly.
External Flue Installation
Locate the air duct/terminal assembly into the flue elbow
assembly as shown in diagram 6.10, making sure of
correct terminal alignment of the “TOP”.
Mark the position of the air duct terminal assembly
securing holes and drill two 3mm diameter holes through
the air duct/terminal assembly.
Fix the self adhesive seal to the air duct,
see diagram 6.11.
From outside, place the air duct/terminal assembly and
flue duct into the flue hole. Make sure that the flue
terminal is correctly positioned and sticking out the
correct distance from the outside wall face,
see diagram 6.11.
Note. The foam seal is a tight fit in the wall sleeve, so
either the wall sleeve will need to be rigidly fixed in the
wall, that is, the cement has fully set or it can be held
from the other side whilst inserting the flue assembly.
3mm
DRILL SIZE
AIR DUCT/TERMINAL
& FLUE DUCT
ASSEMBLY
FLUE
ELBOW
ASSEMBLY
SCREW (2)
3151
Diagram 6.9
FLUE ELBOW /
DUCT ASSEMBLY
3150
FLUE DUCT
SECURING
SCREW (2)
FLUE ELBOW
ASSEMBLY

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220678B
FLUE TERMINAL Diagram 6.11
Locate the flue duct into the air flue elbow assembly and
secure with the screw provided.
Secure the air duct terminal to the flue elbow with the
two self tapping screws supplied in the loose items pack,
making sure that the flue duct is correctly located into
the terminal, see diagram 6.11, then seal with the tape
provided.
7.1 Gas Connection
The gas supply can be connected from below or through
the wall at the rear of the boiler, see diagram 7.1 for
position.
Refer also to Section 1.7.
Make the gas connection to the gas service cock.
Slacken or remove the securing strap, whilst making the
connection. Do not subject the gas service cock to heat.
7.2 Water Connections
Provision is made for the flow and return pipes to be
connected from above, if required, passing down either
side of the boiler, see diagram 7.2 for clearances.
Note. Take care that any pipework connected from
above within the boiler mounting frame will clear the
expansion vessel.
Clean out the heating system before connecting the
boiler.
Make the connections to the heating system by way of
the isolating valves, see diagram 7.1.
Slacken or remove the securing straps whilst making the
connections. Do not subject the valves to heat.
Make sure that the drain points on the valves are
positioned toward the front of the boiler, also that the
drain and operating screw heads are accessible.
7.3 Safety Valve Discharge
WARNING. It must not discharge above an entrance or
window or any type of public access area.
A discharge pipe is supplied loose with the boiler, which
when fitted to the safety valve, will terminate below the
boiler at the notch, see diagram 7.1.
This must be extended, using not less than 15mm od
pipe, to discharge, in a visible position, outside the
building, facing downward, preferably over a drain.
The pipe must have a continuous fall and be routed to a
position such that any discharge of water, possibly
boiling water, or steam cannot create a hazard to persons
or damage to property or external electrical components
or wiring.
Note. To make future servicing easier it is advisable to
use a compression type fitting when extending the
discharge pipe.
WALL SLEEVE
STD FLUE TERMINAL = 63
LONG FLUE TERMINAL = 61
*
*
FLUE
TERMINAL
FLUE
DUCT
Outside Wall Face
3152
3153
'NOTCH' MARKING POSITION OF
SAFETY VALVE DISCHARGE
30
66
27
27 23
33 346
GAS
CONNECTION WATER
CONNECTION
SLOT (CLOSED) DRAIN
POINT SLOT
(CLOSED)
GAS SERIVCE COCK
BOILER CONNECTIONS Diagram 7.1
WATER ISOLATION
VALVES
SECURING STRAPS
6 Installing the Flue
SEAL
7 Gas, Water and Electrical Connections

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15 220678B
7 Gas, Water and Electrical Connections
Diagram 7.2
ELECTRICAL PLUG Diagram 7.3
UPWARD ROUTING
OF PIPEWORK
7.4 Electrical Connections
WARNING. The boiler must be earthed.
Take the electrical connector from the loose items pack
and remove the two screws and cover, see diagram 7.3.
Using PVC insulated cable at least 0.75mm2(24/0.2mm)
to BS6500 Table 16 of a suitable length connect the
mains supply cable to the appropriate terminals of the
connector, see diagram 7.3.
Standard colours are, Brown - Live (L);
Blue - Neutral (N); Green/Yellow - Earth (E).
The mains cable outer insulation must not be cut back
external to the connector, see diagram 7.3.
Make the earth conductor of a greater length than the
current carrying conductors so that if the conductor is
strained the earth would be the last to become
disconnected.
It is essential that the polarity is correct.
After completing the connections secure the cable with
the connector’s cover using the two screws previously
removed, making sure no basic insulated wire is
accessible outside of the connector, see diagram 7.3.
Clip the electrical connector into position on the boiler
mounting frame and secure the mains cable with the
cable clamp immediately behind the connector.
If necessary also secure the cables to the wall using
suitable cable clips.
Keep cables away from hot surfaces
Carry out preliminary electrical system checks, using a
suitable Multimeter, that is, earth continuity, polarity,
short circuit and resistance to earth.
7.5 Heating System Controls
It is recommended that the system is controlled by a time
switch and room thermostat, proprietary control system
or by thermostatic radiator valves. For guidance on the
use of thermostat radiator valves refer to the current
issue of BS7478.
3155
3156
COVER
CONNECTOR
N
L
E
EXPANSION
VESSEL
POSITION
52
93
44
44
235
GAS CONNECTION
WATER CONNECTION
Note: Keep any pipework
clear of shaded area.
CABLE
CLAMP
MAINS
CABLE

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220678B
8 Boiler and Flue Fixing
FASCIA / SAFETY VALVE Diagram 8.2
8.1 Mounting the Boiler
After installing the boiler mounting frame, gas and
water, making the electrical connections and preparing
the flue components continue as below:
Lift the boiler into position, hooking it onto the boiler
mounting frame at the top, see diagram 8.1 then loosely
fit the two, previously removed, boiler securing screws
at the top, see diagram 5.4.
Locate the water pipes into the isolation valves and the
gas service cock union halves, see diagram 5.3.
After positioning the location studs into the clips, see
diagram 5.4, fully push the boiler back to the mounting
frame.
Make the compression joint on the isolating valves and
join the gas service cock union. Secure the valves and
gas service cock with the securing straps.
Secure the boiler by tightening the two fixing screws at
the top.
To fit the discharge pipe to the safety valve, release the
single securing screw and pivot forward the fascia and
control board assembly (PCB), see diagram 8.2.
Secure the discharge tube with the nut and olive supplied
in loose items pack, see diagram 8.2.
Refit fascia control board assembly (PCB).
Connect the plug and socket of the electrical connector
together, see diagram 8.3.
3158
FASCIA
SECURING
SCREW (2)
FASCIA/
CONTROL
BOARD
SECURING
SCREW
DISCHARGE
TUBE
OLIVE
UNION
NUT
CONTROL THERMOSTAT
CONTROL KNOB
BOILER MOUNTING Diagram 8.1
3200
LOCATION
CLIPS
and
STUDS(S)
UNION
CONNECTORS

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8 Boiler and Flue Fixing
8.2 Flue Assembly to Boiler - Connection
NOTE. The fan could be fittedwith transit clips, see
diagram 8.6, which will need removing.
Slacken but do not remove the fan securing screws and
flue hood nuts, see diagram 8.4.
Secure the flue assembly to the spigot on top of the
boiler, see diagram 8.5.
Tighten the fan securing screws and flue hood nuts
previously slackened, see diagram 8.4.
Diagram 8.3
FLUEHOOD / FAN Diagram 8.4
ELECTRICAL
CONNECTOR
3159
CABLE
CLAMP
ELECTRICAL
CONNECTOR
3201
FAN
SECURING
SCREW (2)
FLUEHOOD
SECURING
ANGLE WING NUT
MAINS
CABLE
Diagram 8.5
FLUE ASSEMBLY
CONNECTION
3161
SECURING
SCREW (2)
FLUE DUCT ASSEMBLY
and FLUE ELBOW
FLUE
SPIGOT
Diagram 8.5
TRANSIT CLIPS
FRONT REAR
4856

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18
220678B
9 Completion and Commissioning
9.1 System Commissioning
Commissioning must only be carried out by a competent
person in accordance with the current issue of BS6798.
Check that the boiler is isolated from the electrical
supply at the external isolator.
Open the two water isolating valves, slots in line with
the length of the valves, see diagram 9.1.
Flush out the whole system.
Refill the system, check the operation of the safety
valve, by allowing the water pressure to rise until the
valve operates. The valve should open within +/-0.3bar
(+/-4.3lbf/in2) of the 3 bar, preset, pressure. Where this
is not possible carry out a manual check and test.
Clear any air locks and check for water soundness.
Release cold water to initial system design pressure.
Gas Soundness Test - Pilot
Temporarily disconnect the black cable from the main
burner multifunctional control solenoid and insulate the
connector with insulation tape to prevent the main burner
from lighting.
Turn the gas service cock “On”, the slot in line with the
length of the cock, see diagram 9.3.
WARNING: The multifunctional control and fan
operate on mains voltage, the terminals will become
“Live”.
With the control thermostat control knob in the “O”
“Off” position switch on the electrical supply to the
system.
Turn the control thermostat control knob fully clockwise
to “MAX”, the fan will start, sparks will be generated
and the pilot burner will light.
Check around pilot connections for gas soundness with a
suitable leak detection fluid.
Turn the control thermostat control knob fully anti-
clockwise to “O” and isolate the boiler from the
electrical supply.
Remove the insulation tape and refit the black cable to
the pilot solenoid valve.
3202
FILLING / VENTING Diagram 9.1
IMPORTANT
THE CAP ON THIS
AIR VENT SHOULD
NOT BE REMOVED
OR REPLACED
DRAIN
POINT SLOT
OPEN
WATER
ISOLATING
VALVE

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19 220678B
9 Completion and Commissioning
BOILER CONTROLS Diagram 9.2
GAS SERVICE COCK Diagram 9.3
9.2 Initial Lighting and Testing and
Adjustment
The set pointer on the pressure gauge should be set to
coincide with the cold fill pressure.
Refit the inner case, securing it with the four screws
previously removed, see diagram 9.1.
Make sure that the case is correctly fitted and sealed.
Identify the controls by reference to diagram 9.2.
Check that the boiler is isolated from the electrical
supply.
Make sure that the control thermostat control knob is
turned to “O” the “off” position.
The pilot gas rate is preset and cannot be adjusted.
For future reference attach the self adhesive arrow
indicator, from the loose items pack, to the data label
against the rating that the boiler is going to be set to.
Remove the main burner pressure test point screw
located on the underside of the gas manifold and fit a
suitable pressure gauge, see diagram 9.2.
Make sure that any remote controls are calling for heat.
WARNING. The multifunctional control and fan
operate on MAINS voltage, terminals will become
“LIVE”.
Switch on or connect the electrical supply to the boiler
and heating system, neon 1 will light.
'SLOT' shown on
3164
GAS SERVICE COCK
GAS
PRESSURE
ADJUSTMENT
SCREW
COVER
NEON
WARNING
LIGHT
CONTROL
THERMOSTAT
CONTROL
PRESSURE
TEST
POINT
3163
PRESSURE
GAUGE

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220678B
9 Commissioning and Completion
9.3 Testing - Electrical
Checks to ensure electrical safety should be carried out
by a competent person.
In the event of an electrical fault after installation of the
system. preliminary electrical system checks as below
should be carried out.
1. Test insulation resistance to earth of mains cable.
2. Test the earth continuity and short circuit of all
cables.
3. Switch on the electrical supply to the boiler, neon 1
will light. Test the polarity of the mains supply.
Turn the control thermostat control knob fully clockwise
to the maximum setting, which is about 82oC (180oF),
neon 2 will light.
Note: The burner will not light between “O” and “MIN”.
The lighting sequence is automatic, as follows:
The fan operates.
The spark ignition operates.
The pilot solenoid opens.
The pilot burner lights.
The ignition spark stops.
The main solenoid opens
and after a short period of time the main burner will
light, check this by looking through the viewing window.
The main burner will remain alight until switched off,
either by the control thermostat or a remote system
control.
To make sure that the flame supervision device is
working correctly the following should be done.
1. With the main burner alight, turn the gas service
cock “Off”, see diagram 7.1.
After a short period the main burner and pilot will
go out.
2. The correct working of the flame supervision device
is shown by neon 4 going out within 10 seconds and
the ignition spark starting up.
Neons 1, 2 and 3 should stay alight.
3. If the above does not happen, refer to fault finding,
Section 12.
4. To carry on turn the gas service cock “On”, see
diagram 9.3.
When the boiler switches “Off”, both the pilot and main
burner go out and the fan stops. The automatic lighting
sequence will operate again when heat is required.
The indicator lights on the control board (PCB) are an
aid to fault finding, for details, refer to Section 12. CASE SECURING Diagram 9.4
9.4 Testing - Gas
Test for gas soundness around the boiler gas
components, using a suitable leak detection fluid.
Check the main burner gas pressure at least 10 minutes
after the burner has lit, refer to Data label or Appliance
Data, Table 2.
If the gas pressure requires adjustment, remove the screw
cover, see diagram 9.2 for access to the main burner
pressure adjustment screw. Adjust the gas pressure to
obtained the required setting (turn anti-clockwise to
decrease).
Should any doubt exist about the gas rate, check it using
the gas meter test dial and a stop watch, at least 10
minutes after the burner has lit, make sure that all other
gas burning appliances and pilot lights are off.
The rates are as shown in Table 4.
Turn the control thermostat knob to “O” “Off”. Remove
the pressure gauge from the test point and refit the screw,
ensuring that a gas tight seal is made.
When the control thermostat is turned to “O” “Off”
position, by hand, wait at least 30 seconds before turning
“On” again.
There may be an initial smell given off from the boiler
when new, this is quite normal and will disappear after a
short period of time.
220377B
3165
OUTER
CASE
SECURING
SCREW
OUTER CASE
}
}neon 4 will light
neon 3 will light