Glowworm Space Saver K-F-B 30 User guide

Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
One Contact Local Service
Customer Services:
Tel: [phone]
Fax: [phone]
221051B.01.98
To be left with user
4757
S P A C E S A V E R
K .F .B
30 GC 41 319 08
40 GC 41 319 09
50 GC 41 319 10
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.
Fully Pumped system.
Open Vented or Sealed.
Fanned Flue Boiler
Installation and Servicing Instructions

2
221051B
2
SECTION
Section Title Page No
Contents Location Map
1
2
3
4
5
6
7
8
9
10
11
12
13
Control ofSubstances Hazardous to Health
2890
BELPER
Milford
Site
A6 DERBY
MILFORD
A6 MATLOCK
A519 ASHBOURNE
B6013 RIPLEY
A609 NOTTINGHAM
Nottingham Rd
Site
N
Belper and Milford
Factory Sites
Belper
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.
The adhesives and sealants used in this appliance are cured and give no known hazard in this state.
Insulation and Seals
Ceramic fibre and glass fibre used in insulation panels, rope and gaskets.
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 to the eyes or severe irritation to the skin seek medical attention.
Thermostat
This contains a very small amount of xylene in the sealed phial and capillary. If broken, under normal circumstances the fluid does not
cause a problem, but in cases of skin contact, wash with cold water.
If swallowed drink plenty of water and seek medical attention.
Cut-Off Devices
These contain activated charcoal and a very small amount of chlorodifluormethane in 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.
GENERAL ........3
WATER SYSTEMS ........7
BOILER LOCATION ........11
FLUE and VENTILATION .......13
FLUE INSTALLATION ........15
INSTALLATION ........ 21
COMPLETION
and COMMISSIONING ........29
FRONT PANEL
ASSEMBLY ........34
USER INFORMATION ........35
SERVICING ........36
FAULT FINDING ........41
REPLACEMENT
OF PARTS ........46
SPARES ........ 51

3221051B
3
SECTION
General 1
72.5
350
WATER
CONNECTIONS
22mm COMPRESSIONS
GAS CONNECTION
Rc1/2"(1/2 "B.S.P.T.)
125
102
FRONT VIEW
BOILER OUTLINE
50 63
REAR FLUE
OUTLET
125
687
105
345
358
FRONT VIEW SIDE VIEW
700-
728 130
285-
315
40
SIDE FLUE
OUTLET
TOP VIEW
R F
TOP FLUE
OUTLET
45
35
All dimensions are in millimetres
2885
70
115
15
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 Gas Safety (Installation
and Use) Regulations, be handed to the
user on completion of the installation.
Important Notices
This boiler is for use only on G20 gas.
This boiler must have fully pumped
circuits, but is suitable for use with open
vented or sealed water systems.
This boiler is not suitable for outdoor
locations.
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.
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:-
BS6798, BS5440 Part 1 and 2, BS5546
Part 1, BS5449, BS6891, BS4814,
BS7074 Part 1 and 2, BS6700, BS7478,
BS7593, BS7671.
Manufacturer’s instructions must not be
taken as overriding statutory
requirements.

4
221051B
4
SECTION
General
1
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 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 B.S.I. Certification of the boiler, the
warranty and could also infringe the
current issue of the Statutory
Requirements.
CE Mark
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 body 0086.
Product/production certified:
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 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.
Space Saver K.F.B 40pace Saver K.F.B 40
pace Saver K.F.B 40pace Saver K.F.B 40
pace Saver K.F.B 40
G.C.Number4131909
Space Saver K.F.B 50pace Saver K.F.B 50
pace Saver K.F.B 50pace Saver K.F.B 50
pace Saver K.F.B 50
G.C.Number4131910
Space Saver K.F.B 30Space Saver K.F.B 30
Space Saver K.F.B 30Space Saver K.F.B 30
Space Saver K.F.B 30
G.C.Number4131908
3038
Data Label Position

5221051B
5
SECTION
General 1
in wg 4.3 5.3 4.0
mbar 10.8 13.1 10.0
in wg 6.1 6.7 5.0
mbar 15.3 16.6 12.4
Btu/h 31,566 44,136 56,570
kW 9.25 12.9 16.58
Btu/h 37,500 50,000 62,500
kW 11.0 14.65 18.32
Btu/h 20,000 30,000 40,000
kW 5.86 8.79 11.72
in wg 2.7 3.8 3.3
mbar 6.8 9.4 8.1
Btu/h 30,000 40,000 50,000
kW 8.79 11.72 14.65
Btu/h 25,000 35,000 45,000
kW 7.33 10.25 13.19
Nominal min
Heat med
Input max
(Gross)
Nominal min
Heat med
Ouput max
Burner min
Setting med
Pressure max
Space Saver Space Saver Space Saver
Range Rating K - F - B K - F - B K - F - B
30 4 0 5 0
Btu/h 25,476 38,217 50,630
kW 7.47 11.2 14.84
Space Saver Space Saver Space Saver
Model K - F - B K - F - B K - F - B
30 4 0 5 0
Lifting 25.0kg 25.0kg 25.0kg
Weight (55lb) (55lb) (55lb)
Total 30.0kg 30.0kg 30.0kg
Weight (dry)* (66lb) (66lb) (66lb)
Water 1.7 litres 1.7 litres 1.7 litres
Content (0.37 gal) (0.37 gal) (0.37 gal)
Gas Rc1/2Rc1/2Rc1/2
Connection (1/2BSPT) (1/2" BSPT) (1/2" BSPT)
Water 22mm 22mm 22mm
Connection Compression Compression Compression
Electrical 240V~50Hz fused 3A max
supply
Internal Fuse to BS4265 sheet 2. Type F1A
Fuse Rating
Power rating 55W
* Note: The weight of the water is negligible
Range Rating
The boiler is range rated and may be
adjusted to suit individual system
requirements, refer to the relevant
column of the table.
DataTable

6
221051B
6
SECTION
General
1
Gas Supply
Electrical Supply
DrainingTap
SafetyValve
The gas installation shall 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 for
soundness using the pressure drop method and
suitable leak detection fluid, purge in accordance
with the above standard.
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.
Connection of the boiler and system controls to the
mains supply must be through a common isolator
and must be fused 3A maximum. This method of
connection should be, preferably, an unswitched
shuttered socket outlet and 3 pin plug, both to the
current issue of BS1363.
Alternatively, a double pole isolating switch may be
used, provided it has a minimum contact separation
of 3mm in both poles. The isolator should be
clearly marked showing its purpose. See also
Section 6, Electrical Connection and System
Controls.
Wiring to the boiler must be to the current issue of
BS6500 Table 16, not less than 0.75mm2(24/
0.20mm).
The boiler is provided with a draining tap at the
lower right hand side for draining the heat
exchanger in the event of the boiler being out of use
during freezing conditions.
A draining tap must also be provided at the lowest
points of the system which will allow the entire
system and hot water cylinder to be drained.
Draining taps shall be to the current issue of
BS2879.
A safety valve need not be fitted to an open vented
system.

7221051B
7
SECTION
2
Water Systems
Bypass
Inhibitor
PRESSURE DROP OF BOILER
Flow rate (litres / minute)
Water pressure drop (mm head of water)
Water pressure drop (inches head of water)
Flow rate (gallons / minute)
0123456
0
50
40
30
51015202530
0
250
500
750
1000
1250
1500
0
10
20
30
40
50
60
UNIT
litre / min.
gal / min.
7.6
1.7
30
11.5
2.5
40
15.3
3.4
50
11.5
2.5
30
15.3
3.4
40
19.1
4.2
50
Min.
HEAT SETTING
At 11˚C (20˚F) differential
WATER FLOW RATE
Max.
4779
Notes: Open Vented
and Sealed Systems
Pump
See chart for pressure drop of the boiler.
The pump should be fitted in the flow
pipe from the boiler and have isolating
valves each side, integral if possible.
The variable duty pump should be set to
give a temperature difference of 11oC
(20oF) between flow and return with the
thermostat set at “MAX” which is about
82oC (180oF).
High resistance microbore systems may
require a higher duty pump.
A BYPASS MUST BE FITTED, see also Section 7.
The flow through the boiler must not be allowed to
fall below......
Space Saver KFB30 - 6.4litres/min (1.4galls/min)
Space Saver KFB40 - 8.4litres/min (1.8galls/min)
Space Saver KFB50 - 10.5litres/min (2.3galls/min)
Where the water system can allow the boiler and
pump to operate on bypass only, the bypass must be
at least 2.0metres away from the boiler.
If an inhibitor is to be used refer to the current issue
of BS5449 and BS7593, contact a manufacturer for
their recommendations as to the best product to use.
When using in an existing system take special care to
drain the entire system, including the radiators, then
thoroughly cleaning out before fitting the boiler
whether or not adding an inhibitor.

8
221051B
8
SECTION
BOILER
CEILING
THE WATER LEVEL IN STATIC CONDITION
MUST BE ABOVE THE BEND IN THE PIPE.
45˚
APPROX.
TO
COLD
FEED
TOP OF THE
APPLIANCE
WITHOUT
CASE
NOTE: VENT PIPE AND COLD
FEED PIPE MUST BE
MADE FROM Ø22 TUBE.
COLD
FEED
RETURN
SLIGHT RISE
FLOW
TO
PUMP
150mm
MAX
300mm
MIN
120mm
MIN
300mm
MIN
300mm
MAX
620mm
MIN
CENTRE
LINE
Water Sysems (Open Vented)
1
2887
Low Head Installation
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 27.5 metres (90ft) above the
boiler.
The cold feed supply must be 15mm
minimum size.
The vent must rise continuously and be
unrestricted.
It is important that the relative positions
of the pump, cold feed and open vent are
as shown.
Domestic HotWater
Cylinder
The hot water cylinder must be of the
double feed fully indirect type. Not the
self priming type.
6003
FEED AND
EXPANSION
CISTERN
22mm VENT
(MIN.)
15mm (MINIMUM)
COLD FEED
OPEN VENTED FULLY PUMPED WATER SYSTEM
RECOMMENDED RELATIONSHIP BETWEEN
PUMP COLD FEED AND VENT
450mm
MIN.
HEIGHT
1150mm
MIN.
RETURN FLOW
CYLINDER
PUMP
HEATING
150mm
MAX.
There must always
be a cold water path
to the return
connection
of the boiler.
BOILER 15mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE
FLOW
RET.

9221051B
9
SECTION
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
15mm (min)
BY-PASS WITH
LOCKSHIELD
VALVE
RETURN
Water Systems (Sealed) 2
5812
ExpansionVessel
SealedWater Systems
The installation must comply with the
appropriate requirements of the current
issue of BS5449 Part 1, BS6798, BS4814
and BS7074 Part 1 and 2.
See the diagrammatic layout.
SafetyValve
A safety valve must be fitted to a sealed
water system.
It shall be preset, non-adjustable with a
lift pressure of 3bar, incorporating seating
of a resilient material, a test device and a
connection for drain.
Where a safety valve is fitted the drain
from it must be routed clear of any
electrical fittings but positioned so that
any discharge can be seen.
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, unless laid
down differently by the manufacturer.
The expansion vessel volume depends on the total water
system volume and the initial system design pressure. For
any system an accurate calculation of vessel size is given
in the current issue of BS7074 Part 1 Section 7.2.
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 Part 1.
The charge pressure must not be less than the static head
of the system, that is, the height of the highest point of the
system above the expansion vessel.
The water capacity of the boiler is given in the Data
Table.

10
221051B
10
SECTION
Water Systems (Sealed)
2
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.
Domestic HotWater
Cylinder
SINGLE FEED INDIRECT
CYLINDERS ARE NOT SUITABLE
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.
UNVENTED
Where a storage system will not have a
vent to atmosphere the installation must
comply with the Building Regulations and
any local Water Company Bylaws, see
also the current issue of BS5446 and
BS6700.
If fitting into an existing system the local
authority must be informed.
Water Make Up
Provision should be made for replacing
water loss 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 either the heating circuit
of the hot water cylinder.
Alternatively, provision for make up can
be made by pre-pressurisation of the
circuit.
Filling Sealed Systems
Provision for filling the system at low
level must be made. Three methods are
shown in the diagram. There must be no
permanent connection to the mains water
supply, even through a non-return valve.
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
0051M

11 221051B
11
SECTION
3
Boiler Location
WHERE EXTERNAL ACCESS TO THE
FLUE IS NOT PRACTICAL THEN
CLEARANCE MUST BE ADEQUATE
TO PERMIT INSTALLATION OFF THE
FLUE ASSEMBLY
✽
70mm
10mm 5mm
5mm
5mm
5mm
10mm
100mm
2891
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 complete weight, see Data Table.
Boiler Clearances
The boiler must be positioned so that at
least the minimum operational and
servicing spaces are as shown.
500mm

12
221051B
12
SECTION
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.
Boiler Location
2
S P A C E S A V E R K . F . B 3 0
VENTILATION HIGH LEVEL LOW LEVEL
REQUIREMENTS VENT AREA VENT AREA
FROM ROOM
OR SPACE
FROM
OUTSIDE
99cm2(15in2) 99cm2(15in2)
50cm2(8in2) 50cm2(8in2)
S P A C E S A V E R K . F . B 4 0
VENTILATION HIGH LEVEL LOW LEVEL
REQUIREMENTS VENT AREA VENT AREA
FROM ROOM
OR SPACE
FROM
OUTSIDE
133cm2(21in2) 133cm2(21in2)
67cm2(10in2) 67cm2(10in2)
S P A C E S A V E R K . F . B 5 0
VENTILATION HIGH LEVEL LOW LEVEL
REQUIREMENTS VENT AREA VENT AREA
FROM ROOM
OR SPACE
FROM
OUTSIDE
168cm2(26in2) 168cm2(26in2)
84cm2(13in2) 84cm2(13in2)
Cupboard or
Compartment
Ventilation
Where the boiler is fitted in a cupboard
or compartment, permanent high and
low level ventilation must be provided.
The ventilation areas required are given
in the Table.
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.
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 for easy removal
of the boiler.
Flue andVentilation
The flue must be installed in accordance
with the current issue of BS5440 Part 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.

13 221051B
13
SECTION
4
Flue and Ventilation
ADIRECTLY BELOW AN OPENABLE WINDOW, AIR VENT, 300
OR ANY OTHER VENTILATION OPENING
BBELOW GUTTER, DRAIN/SOIL PIPE 75
CBELOW EAVES 200
DBELOW A BALCONY OR CAR PORT 200
EFROM VERTICAL DRAIN PIPES AND SOIL PIPES 75
FFROM INTERNAL OR EXTERNAL CORNERS 300
GABOVE ADJACENT GROUND OR BALCONY LEVEL 300
HFROM A SURFACE FACING THE TERMINAL 600
IFACING TERMINALS 1200
JFROM OPENING (DOOR/WINDOW) 1200
IN CARPORT INTO DWELLING
KVERTICAL FROM A TERMINAL 1500
LHORIZONTALLY FROM A TERMINAL 300
MIN.
SPACING
(mm)
MINIMUM SITING DIMENSIONS
FOR FLUE TERMINALS
A
A
FGEA
G
G
G
B,C B,C
FF
K
K
K
C
G
LL
Car Port etc.
H,I
JD
F
K
0103M
4783
Terminal Position
The minimum acceptable spacings from
the terminal to obstructions and
ventilation openings are as shown in the
diagram.
Where the terminal is fitted within
600mm (24in) below plastic guttering an
aluminium shield 1500mm (5ft) long
should be fitted to the underside and
immediately beneath the guttering or
eaves.
Where the terminal is fitted within
450mm (18in) below eaves or painted
guttering an aluminium shield 750mm
(2ft6in) long should be fitted to the
underside and immediately beneath the
guttering or eaves.
Terminal Protection
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 terminal guard can be bought
from:
Tower Flue Components Ltd.,
Morley Road,
Tonbridge,
Kent.
TN9 1RA
their reference K3.

14
221051B
14
SECTION
t o
Flue and Ventilation
2
t o
Rear Flue Lengths
Distance'R'
STD 75mmto692mm
1m 692mmto1022mm
2m 1022mmto2022mm
step
5
step
1
step
step
16
11
&
t o
step
16
step
6
2876
Flue Position and
Length
Note. If a longer flue duct is required
DO NOT extend the ducting. A special
long flue system and terminal can be
supplied and MUST be used.
DETERMINE FLUE APPLICATION,
LENGTH, AND TERMINAL
POSITION BEFORE PROCEEDING.
Refer to the relevant diagrams in
Section 4.
For wall thickness of less than 300mm
the boiler can be fully installed from
inside.
For a wall thickness of over 300mm the
cut hole will need to be made good from
the outside.
The rear and side flue assemblies are
designed for internal installation, but
should it be necessary due to insufficient
clearances or boiler location they can be
installed from the outside.
REAR FLUE APPLICATION
FOLLOW
FLUE INSTALLATION
SIDE FLUE APPLICATION
FOLLOW
FLUE INSTALLATION
R
2877
Side Flue Lengths
Distance'S'
STD 75mmto692mm
1m 692mmto1022mm
2m 1022mmto2022mm
S

15 221051B
15
SECTION
step
5
Flue Installation
step
1
step
3No. 10x11/2in
SCREW
300mmMAX
LENGTH
Q
Q
115mm
MINIMUM
HOLE
WALLPLATE/
TEMPLATE
2892
2
WALL SLEEVE
WALLPLUG
5.5mm DRILL SIZE
Rear Flue Application
Having selected the boiler location
with due regard to the terminal
position;
Using an adhesive tape temporarily
position the wallplate/template on the
wall.
Mark out the centre and cut the hole
for the flue using, preferably, a 115mm
minimum core drill.
If the wall thickness “Q” is less than
300mm cut the wall sleeve to the
required length.
Fit the wall sleeve.
Make good around the wall sleeve at both
internal and external wall faces (through
the wall sleeve if internal access is only
available).
If the wall thickness “Q” is greater than
300mm the wall sleeve must be fitted
flush with the INSIDE wall face. If the
inner end of the liner sticks out into a
cavity then, if desired, the wall liner can
be trimmed back to the depth of the inner
skin of the brickwork. Make good at the
internal wall face, leave the external wall
face until later.
Reposition the wallplate/template
ensuring alignment with the flue
hole. Mark the top and bottom
boiler mounting hole positions.
Remove wallplate/template, drill
holes and then secure wallplate/
template to the wall with the fittings
provided in the loose items pack.

16
221051B
16
SECTION
Flue Installation
5
Q
Q+13mm
STANDARD
FLUE TERMINAL
Q
Q+11mm
2893
step
step
4
5
step
11
Continue at
Flue Duct
Mark the duct to the length
“Q”+11mm then cut square and
remove any burrs.
Air Duct/Terminal
Mark the duct to the length
“Q”+13mm then cut square and
remove any burrs.
1M AND 2M FLUE
TERMINAL

17 221051B
17
SECTION
5
Flue Installation
300mm MAX
LENGTH
5.5mm DRILL SIZE
No. 10x11/2in
SCREW
WALLPLUG
115mm
MINIMUM
HOLE
125mm
Q
Q
2894
step
step
6
step
8
7
Mark and extend the flue horizontal
centre line to the corner of the adjacent
surface.
Mark out and cut the hole for the flue
using preferably, a 115mm minimum
core drill.
Side Flue Application
Having selected the boiler location,
with due regard to boiler clearances
and the terminal position.
Position the wallplate/template on the
wall. Mark the top and bottom boiler
mounting hole positions.
Remove the wallplate/template, drill the
holes and then secure the wallplate/
template with the fittings provided.
WALL SLEEVE
If the wall thickness “Q” is less than
300mm cut the wall sleeve to the required
length.
Fit the wall sleeve.
Make good around the wall sleeve at both
the internal and external wall faces
(through the wall sleeve if internal
access only is available).
If the wall thickness “Q” is greater than
300mm the wall sleeve must be fitted
flush with the internal wall face.
Make good at the internal wall face, leave
the external wall face until later.
If the inner end of the sleeve sticks out
into a cavity then, if desired, the wall
sleeve can be trimmed back to the depth
of the inner skin of the brickwork.

18
221051B
18
SECTION
Flue Duct (Standard or
Long)
Mark the duct to length “S”+11mm then
cut square and remove any burrs.
Flue Installation
5
step
9
2895
step
10
Terminal/Air Duct
(Standard or Long)
Mark the duct to the length “S”+13mm
then cut square and remove any burrs.
S+11mm
S
S+13mm
WALLPLATE
/TEMPLATE
WALLPLATE
/TEMPLATE
S
1M AND 2M FLUE
TERMINAL
STANDARD
FLUE TERMINAL

19 221051B
19
SECTION
Air Duct/Terminal and
Flue Duct Assembly
Locate the flue duct into the air duct/
terminal.
5
Flue Installation
step
step
11
12
Place the sealant from the loose items
pack onto the flue manifold.
Fully locate the flue manifold into the
air duct/terminal and flue duct assembly
as shown, making sure of the correct
alignment of the “TOP”s.
Drill two 3mm diameter holes
through the air duct/terminal and flue
manifold.
Secure the air duct/terminal to the flue
manifold with the two self tapping
screws supplied in the loose items pack.
It should now not be possible to remove
the manifold.
step
13 3mm DRILL SIZE
2896
AIR DUCT/TERMINAL
ASSEMBLY
FLUE
DUCT
SEALANT
AIR DUCT/TERMINAL
AND FLUE DUCT
ASSEMBLY
FLUE MANIFOLD
5mm

20
221051B
20
SECTION
Flue Installation
5
step
14
3039
step
15
WallThickness up to
300mm
Fit the self adhesive foam seal provided
in the loose items pack around the air
duct/terminal at the position shown.
WallThickness over
300mm
Fix the self adhesive foam seal around
the air duct/terminal such that, when
installed, the seal will be within the wall
sleeve.
If the boiler is not to be fitted for
sometime cover the hole in the wall.
On all installations push the flue
assembly into and through the wall
sleeve and hole such that it is within the
wall sleeve and does not stick out into
the room. Do not push the flue assembly
too far into the hole as it has to be pulled
back into the boiler and secured to the
keyhole fixings.
Note: That 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.
step
16
FOAM SEAL
10mm
FOAM SEAL
Q
Q-25mm
WALL
SLEEVE
Q