Glowworm Swift flow 120 User manual

Supplied By www.heating spares.co Tel. [phone]
220674B.03.97
Tobeleftwiththeuser
Installation Instructions
120
Fanned Flue Combination Boiler
G.C. No. 47 313 13
One Contact Total Service
Customer Services:
Tel: [phone]
Fax: [phone]

Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
This is a Cat I 2H appliance

Supplied By www.heating spares.co Tel. [phone]
2
220674B

Supplied By www.heating spares.co Tel. [phone]
3220674B
0175M
Diagram 1.1
ALL DIMENSIONS IN MILLIMETRES
Rc 1/2(1/2in. BSPT)
GAS CONNECTION
22 mm COMPRESSION
CENTRAL HEATING
15 mm COMPRESSION
DOMESTIC WATER
KEY:
58
114
168 331 450
25
2.5
107
66
783
107 66
130
70
1 G e n e r a l
1.1 Important Notice
This boiler is for use on natural gas as distributed in the
United Kingdom and Ireland (G20) and cannot be used
on any other gas.
Certification
The boiler is certificated for safety and performance.
It is, therefore, important that no alteration is made to the
boiler unless approved, in writing, by 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.
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 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.
1.2 Sheet Metal Parts
WARNING. When installing the boiler, care should be
taken to avoid any possibility of injury when handling
sheet metal parts.
1.3 Notes for Information
The instructions consist of three parts, Installation,
Servicing and Instructions for Use. They are the
property of the user and must be handed to them on
completion of the installation.
Materials and equipment should be fit for their purpose
and of suitable quality and workmanship.
1.4 Requirements
The installation of this boiler must be carried out by a
competent person in accordance with the rules in force in
the countries of destination.
Manufacturer’s instructions supplied.
Manufacturer’s instructions must not be taken as
overriding statutory requirements.
1.5 Data Label
The data label is on the inner case cover.
1.6 Data
See Tables 1 and 2.

Supplied By www.heating spares.co Tel. [phone]
4
220674B
1 G e n e r a l
16
17
18
13
4
2
5
6
19
15
14
10
11 9 8 7
13
20
21
22
23
12
Diagram 1.2
KEY
1 - Heat Exchanger
2 - Main Burner
3 - Pilot Burner
4 - Automatic Air Vent
5 - Expansion Vessel
6 - Pump
7 - D.H.W. Hot Outlet
8 - C.H. Return
9 - Gas Supply
10- C.H. Flow
11- D.H.W. Cold Inlet
12- Safety Valve
●Ball valves are fitted in water and gas connections, plus a drain point on all water connections.
✽D.H.W 0.6 to 10bar
working pressure (8.70 to 188lbf/in2)
■Maximum Heating 119 litres
system water (26.2 gallons)
content using with a cold
fitted expansion fill pressure
vessel. of 0.7bar
Electrical supply 240V~50Hz
Electrical rating 130W
Internal Fuse rating: Fuse 1 Type 2AT
Fuse 2 Type 3.15AT
Lift Weight 39.0 kg (85.98 lb)
Total Weight 52.8 kg (116.40 lb)
●Gas connection Rc1/2(
1/
2
in BSPT)
●Heating and return 22mm compression
●Domestic hot water 15mm compression
Safety valve Preset 3bar (43.5lbf/in2)
Safety valve discharge 15mm copper
Water content 1.74 litres (0.38 gallon)
■Expansion vessel capacity 8 litres (1.76 gallons)
Heating cold fill 0.7bar
pressure minimum (10.1lbf/in2)
TABLE 2
✽Boiler starts at an inlet pressure of 0.6bar but requires 0.8bar for maximum output.
■For larger systems use an additional expansion vessel, see Section 4.
NOMINAL kW 29.0 43.5 10.9
HEAT
INPUT Btu/h 98,950 148,420 37,190
NOMINAL kW 23.5 35.2 8.8
HEAT
OUTPUT Btu/h 80,000 120,000 30,000
BURNER m bar 5.6 13.1 0.3
PRESSURE in.wg 2.2 5.3 0.1
APPROX. m3/h 2.8 4.1 1.0
GAS RATE ft3/h 97.6 146.4 36.7
TABLE 1 C.H. Max D.H.W Max MIN
13- Safety Valve Discharge
14- Water Throttle
15- Mini Expansion Vessel
16- Flow Switch
17- Gas/Air Ratio Unit
18- Multi-Functional Control
19- Pressure Switch-Water
20- Air Pressure Switch
21- Venturi
22- Flue Collector
23- Pressure Sensing Probe
FACTORY PRESET TO 60,000Btu/h
0193M

Supplied By www.heating spares.co Tel. [phone]
5220674B
1 G e n e r a l
1.7 Gas Supply
The gas installation must be in accordance with the rules
in force in the countries of destination.
The supply from the governed gas meter must be of
adequate size to provide a steady inlet working pressure
of 20mbar (8in wg) at the boiler.
1.8 Electrical Supply
WARNING: The boiler must be earthed.
The installation must be in accordance with the rules in
force in the countries of destination.
All system components shall be of an approved type.
Connection of the whole electrical system of the boiler
and any heating system controls to the electrical supply,
must be through one common isolator.
Isolation should preferably be by a double pole switched
3A fused spur box, with a minimum separation of 3mm
in both poles. The fused spur box should be readily
accessible and preferably adjacent to the appliance.
It should be identified as to its use.
A fused 3A three pin plug and shuttered socket outlet
may be used instead of the fused spur box, provided that
they are not used in a room containing a fixed bath or
shower.

Supplied By www.heating spares.co Tel. [phone]
6
220674B
0183M
2 B o i l e r P o s i t i o n
✽5
✽5
140
150
✽5
55
800
Diagram 2.1
✽Increase to 25mm clearance from
combustible material
Refer to text, Section 2.2 Clearances,
"Installation Clearances"
2.1 Boiler Position
The boiler must be installed in accordance with the rules
in force of the countries of destination.
The boiler is not suitable for outside installation.
Any electrical switch or boiler control using mains
electricity must be positioned so that it cannot be
touched by a person using the bath or shower.
The boiler must be mounted on a flat wall which is
sufficiently robust to take its weight, refer to Table 2.
If the boiler is to be fitted into a cupboard, compartment
or unusual location, special procedures are necessary.
Make sure that the cupboard or compartment air vents
are positioned to be clear of obstructions at all times,
refer to Section 3.7.
2.2 Clearances
The boiler should be positioned so that at least the
minimum operational and servicing clearances are
provided, see diagram 2.1.
Installation Clearances
For rear flue installation the dimension between the
boiler mounting wall and a permanent facing wall must
be a minimum of “X”, see diagram 3.1 and 3.3, plus
272mm.
For side flue installation the dimension between any
adjacent permanent walls must be a minimum of “Y”,
see diagram 3.2 and 3.3, plus 332mm.
For flue installations where internal clearances are not
practicable, then external installation will be necessary.

Supplied By www.heating spares.co Tel. [phone]
7220674B
3 F l u e a n d V e n t i l a t i o n
Diagram 3.3
Diagram 3.4
REAR FLUE 1,2 and 3 metre
SIDE FLUE 1,2 and 3 metre
Left or Right
Diagram 3.1
Diagram 3.2
WALL THICKNESS ‘X’: 75 to 590mm
DISTANCE ‘Y’: 80 to 528mm
“X”
REAR FLUE - STANDARD
“Y”
SIDE FLUE - STANDARD
Left or Right
4563
4566 4565 4564
1m FLUE DISTANCE ‘Y’: 80 to 828mm
2m FLUE DISTANCE ‘Y’: 80 to 1828mm
3m FLUE DISTANCE ‘Y’: 80 to 2828mm
“Y”
1m FLUE DISTANCE ‘X’: 75 to 890mm
2m FLUE DISTANCE ‘X’: 75 to 1890mm
3m FLUE DISTANCE ‘X’: 75 to 2890mm
Note. All flue assemblies are designed for internal
installation, given that there is sufficient clearances
opposite to the flue for the installation of the flue.
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 over 300mm the external flue hole
will need to be made good from the outside.
If there is insufficient clearance the flue can be installed
from outside.
3.1 Flue
The flue must be installed in accordance with the rules in
force in the countries of destination.
3.2 Flue Position and Length
The air and flue ducting connect to the top of the boiler
using a flue elbow and can be positioned in one of three
directions:
rearward, left or right.
The standard flue will provide the range shown in
diagram 3.1 for a rear flue or diagram 3.2 for a side flue.
If a longer flue duct is required, do not extend the
ductings. A 1, 2 or 3metre flue system and elbow/
terminal kit must be used and can be supplied. This will
provide the range shown in diagram 3.3 for a rear flue,
diagram 3.4 for a side flue.
A Flue Bend Kit or Vertical Flue Kit can be supplied
with instructions.
3.3 Terminal Position
The minimum acceptable siting dimensions for the
terminal from obstructions, other terminals and
ventilation openings are shown in diagram 3.5.
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 made of plastic
sheeting. If the car port comprises of a roof and two or
more walls, seek advice from the local gas undertaking
before installing the boiler.
If the terminal is fitted within 600mm below plastic
guttering, an 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.
“X”

Supplied By www.heating spares.co Tel. [phone]
8
220674B
3 F l u e a n d V e n t i l a t i o n
MINIMUM SITING DIMENSIONS
FOR FANNED FLUE
TERMINALS POSITION
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
SPACING
in mm
0103M
Under Car Port etc.
H,I
JD
F
K
A
A
FGEA
G
G
G
B,C B,C
FF
K
K
K
C
G
LL
3.4 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.
The guard should be similar to that shown in
diagram 3.5.
3.5 Timber Frame Buildings
If the boiler is to be installed in a timber frame building,
seek advice from the local gas undertaking or from
Hepworth Heating Ltd.
3.6 Room Ventilation
The boiler is room sealed, so when it is installed in a
room or space, a permanent air vent is not required.
3.7 Cupboard or Compartment Ventilation
If the boiler is to be fitted in a cupboard or compartment,
permanent high and low level air vents must be provided
The vents must have at least the effective areas as given
in Table 3.
High Vent 392cm2(60.8in2) 196cm2(30.4in2)
Low Vent 392cm2(60.8in2) 196cm2(30.4in2)
TABLE 3
Position Air from Air Direct
of Room or from
Air Vent Internal space Outside
Diagram 3.5
4783

Supplied By www.heating spares.co Tel. [phone]
9220674B
4 H e a t i n g S y s t e m
Diagram 4.1
AVAILABLE PUMP HEAD SYSTEM HEATING LOAD
FLOW RATE
✽ACCEPTABLE
DIFFERENTIAL
RANGES
SYSTEM DIFFERENTIAL TEMPERATURE
✽
30
40
50
60
70
80
Btu/h x1000
10
12
14
16
18
20
22
kW
0
5
10
15
20
FEET
1
2
3
4
5
6
M
11 15 20 25 30 35 Litres/Min
2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 Gallons/Min
0
5
0
5
10
15
20
25
30
35
10
11
15
17
20
˚C ˚F
PUMP CURVE - SETTING 2
PUMP CURVE - SETTING 3
0194M
4.1 General Notes
The boiler is for use in sealed water systems only.
4.2 Safety Valve
The safety valve is an integral part of the boiler and it
cannot be adjusted.
4.3 Pressure Gauge
A pressure gauge is incorporated into the boiler to
indicate the system pressure.
4.4 Pump
The pump is integral with the boiler.
The remaining circulating pressure head available from
the pump is shown in diagram 4.1.
4.5 Expansion Vessel
The boiler has an integral expansion vessel with a
capacity of 8Litres (1.76gallons), with a charge pressure
of 0.75bar.
The maximum heating system water content using the
fitted expansion vessel ranges from 119Litres with a cold
fill pressure of 0.7bar, to 98Litres 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.

Supplied By www.heating spares.co Tel. [phone]
10
220674B
4 H e a t i n g S y s t e m
Diagram 4.2
BOILER
3-LITRE
MAKE-UP
BOTTLE
(if required)
NON-RETURN
VALVE
AUTO AIR
VENT
DOMESTIC
WATER
HOT
COLD SUPPLY
FILLING
POINT
DRAIN
POINT
MIN. 22mm
DIA. BY-PASS
'B'
'A' BY-PASS
VALVE
FLOW CONTROL
VALVE
HEATING
CIRCUIT
RETURN
ADDITIONAL
EXPANSION
VESSEL
(if required)
2818
4.6 Flow Rate
A valve must be incorporated in the main flow or return
of the system, valve “A” shown in the flow in diagram
4.2. This valve must be lockable and positioned so that
inadvertent closure or unauthorised interference is not
possible. The design differential can be between 11ºC
(20ºF) and 17ºC (30ºF), dependent on the system
resistance and the available pump head. The pump
adjuster should normally be left at maximum (3) but in
some cases it is permissible to adjust the pump to a
lower setting (2). See diagram 4.1.
To use diagram 4.1 start with the required heating
system load.
In the example shown the maximum boiler output has
been chosen, 23.5kW (80,000Btu/h).
Draw a horizontal line from the required system
differential temperature axis to intersect the curve. In
the example 11ºC (19.8ºF) has been chosen,
shown . At the point of intersection draw a
vertical line to cross the pump curve. From this point
draw a further horizontal line to determine the available
pump head. In the example 2.4m (7ft9in) is available.
A greater pump head can be achieved by choosing a
higher system differential temperature, up to a maximum
of 3.8m (12ft 6in) at a system differential of 17ºC
(30.6ºF). The system must be designed such that the
available pump head is not exceeded.
If the heating system load is less than 14.7kW
(50,000Btu/h) then it is permissible to adjust the pump
setting to (2), shown . This results in an
available pump head of 2.1m (7ft). This is the maximum
that can be achieved with the pump at this setting.
4.7 Bypass
It is ESSENTIAL that a bypass of 22mm od minimum is
fitted to all installations. The bypass must have a
lockable valve, “B” in diagram 4.2, incorporated in a
position so that inadvertent closure is not possible.
The bypass MUST be fitted before any system control.
A radiator bypass is NOT recommended.
4.8 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 4.2. Alternatively,
provision for make up can be made by pre-pressurisation
of the circuit.

Supplied By www.heating spares.co Tel. [phone]
11 220674B
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
4 H e a t i n g S y s t e m
Diagram 4.3
4.9 Filling Sealed Systems
Provision for filling the system at a low level must be
made. Three methods of filling are shown in diagram
4.3. There must be no permanent connection to the
mains water supply, even through a non-return valve.
4.10 Corrosion Inhibitor
If an inhibitor is to be used in the system, contact a
manufacturer so that they can recommend their most
suitable product.
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.
4.11 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.
The flow and return isolation valves are provided with
drain points for boiler heat exchanger drainage.

Supplied By www.heating spares.co Tel. [phone]
12
220674B
5 D o m e s t i c H o t W a t e r S y s t e m
5.1 General
The domestic hot water service must be in accordance
with the rules in force in the countries of destination.
5.2 Water Pressure
For the minimum and maximum working pressures of
the domestic hot water circuit of the boiler, refer to
Section 1.6. If the cold water supply pressure exceeds
the maximum, a pressure reducing valve must be fitted
in the supply to the boiler to reduce the pressure to
within the limits given.
5.3 “Hard” Water Areas
In areas where the water is “hard”, that is, more than
200mg/litre, it is recommended that a proprietary scale
reducer is fitted in the cold supply to the boiler.
Check the total water “hardness” using the kit supplied,
in the door, following the instructions given. Consult the
local water company for additional advice.
A double check valve assembly must be fitted upstream
of the scale reducer. For the relative position of the scale
reducer and pressure reducing valve, if required, refer to
the manufacturer’s instructions.

Supplied By www.heating spares.co Tel. [phone]
13 220674B
6 A p p l i a n c e a n d F l u e P r e p a r a t i o n
Diagram 6.3
FAN SECURING
SCREWS
Diagram 6.2
Diagram 6.1
Diagram 6.4
OUTER CASE
SECURING
SCREW (2)
SELECTOR
SWITCH
DOOR
OUTER CASE
PLASTIC
PLUGS (2)
COVER
PLATE
VIEWING
WINDOW
INNER CASE
COVER SECURING
SCREW (4)
SECURING
SCREW (2)
UNIONS (5)
CLIP (5)
LOCATION
CLIPS
DATA
LABEL
ELECTRICAL
PLUG
AIR
PRESSURE
TUBE
THUMB
SCREW
(2)
45674561
4560
4562
6.1 Unpacking
Remove the top carton and cut out the flue template from
the inner flap.
Open the control door, see diagram 6.1.
Remove the two screws securing the outer case and then
lift it at the top and pull it forwards and off, see diagram
6.1.
Remove the cover of the inner case, secured with four
screws, see diagram 6.2
Slacken flue collector thumb screws.
Remove the fan securing screws.
Disconnect the electrical plug connector and air pressure
tube from the fan, see diagram 6.3.
Pull the fan forwards, at the bottom and rotate to
disengage the fan outlet from rear bracket.
Take care not to damage the seal.
Tilt the fan and withdraw.
Disconnect the gas cock union and the front unions of
the isolation valves, see diagram 6.4.
Slightly loosen the clips of the gas service cock and the
isolating valves.
Remove the two boiler securing screws then remove the
boiler from the mounting frame, by pulling the studs
from the clips and unhooking it at the top.

Supplied By www.heating spares.co Tel. [phone]
14
220674B
6 A p p l i a n c e a n d F l u e P r e p a r a t i o n
Diagram 6.6
0176M
Diagram 6.5
TOP OF
BOILER
300
FLUE
TEMPLATE
(Cut from
carton top
inner flap)
BOILER
MOUNTING FRAME
FIXING POINTS
FLUE
CENTRELINE
0177M
FLUE
CENTRE
LINE
CORNER
(Right Flue) CORNER (Left Flue)
Diagram 6.7
MIN. CLEARANCE
111.5 70
591.5
480
130 Dia.
168 168
130 Dia.
Q
Q300mm MAX
LENGTH
WALL SLEEVE
4443
6.2 Marking
The boiler mounting frame is the same width as the
boiler case. The flue connection is on the top.
Place the boiler mounting frame on the wall in the
required position, see diagram 2.1, to maintain minimum
clearances. 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.
Position the flue template on the wall, the arrow points
on the centres of the two upper fixing points previously
marked, see diagram 6.5 which also gives dimensions.
For a rear flue, mark the position as required.
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 outside.
Mark the position of the circular hole, on the flue exit
wall, using the dimensions given in diagram 6.6.
From the flue position marks, check that the flue
terminal will be in a suitable position, see diagram 3.5.
6.3 Flue Hole Cutting
Having marked out the flue centre, cut a hole for the
flue, using, preferably, a 130mm minimum core drill.
Cut the hole horizontally in the wall, making sure that it
does not slope down toward the boiler.
6.4 Wall Sleeve
If the wall thickness “Q” is less than 300mm cut the wall
sleeve to the required length, see diagram 6.7.
Fit the wall sleeve.
Make good around the wall sleeve at both 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 INSIDE wall face.
If the inner end of the sleeve sticks out into the cavity
then, if desired, the wall sleeve can be trimmed back to
the depth of the inner skin of brickwork. Make good at
the internal wall face but leave the external wall face
until the flue has been fitted.
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.
Drill the four fixing holes and insert wall plugs to suit
No.10x50mm screws.
Secure the boiler mounting frame to the wall using
No.10x50mm screws.

Supplied By www.heating spares.co Tel. [phone]
15 220674B
0180M
7 F l u e P r e p a r a t i o n
Diagram 7.2
OUTSIDE
WALL FACE
"Y"
Diagram 7.1
BOILER
MOUNTING
WALL
"X"
SIDE OF
BOILER
MOUNTING
FRAME
OUTSIDE
WALL
FACE
Diagram 7.3
FLUE ELBOW
FLUE DUCT SECURING
SCREW (1)
AIR DUCT/
TERMINAL
SEALING TAPE
3mm Drill
FLUE DUCT/
ELBOW
FLUE
SPACER
"Y" plus 172
(FLUE DUCT,
AIR DUCT/
TERMINAL
ASSEMBLY)
"X" plus 110
(FLUE DUCT,
AIR DUCT/TERMINAL ASSEMBLY)
7.1 Flue Length
For a rear flue, measure the distance from the outside
wall face to the boiler mounting wall. Check that the
flue length will be suitable, see diagram 3.1 for a
standard flue system or diagram 3.3 for a 2 or 3metre
flue system.
For a side flue, measure the distance from the outside
wall face to the side of the boiler mounting frame.
Check that the flue length will be suitable, see diagram
3.2 for a standard flue system or diagram 3.4 for a 2 or
3metre flue system.
7.2 Rear Flue
Note. Do not cut the flue duct at the pre-drilled end.
Mark the air duct/terminal assembly and the flue duct at
the lengths shown in diagram 7.1 then cut to length,
cutting square and removing any burrs.
7.3 Side Flue
Note. Do not cut the flue duct at the pre-drilled end.
Mark the air duct/ terminal assembly and the flue duct at
the lengths shown in diagram 7.2 then cut to length,
cutting square and removing any burrs.
7.4 Flue Assembly
Locate the flue duct, drilled end, onto the flue elbow and
secure with screw supplied in loose items pack, see
diagram 7.3.
Slide the spacer onto the flue duct.
Locate the flue duct/elbow into the air duct/terminal
spigot and the air duct/terminal into the flue elbow
making sure of the correct alignment of top. Drill the air
duct and secure/seal (external fixing, do not seal) as
shown in diagram 7.3.
4568
0179M

Supplied By www.heating spares.co Tel. [phone]
16
220674B
Diagram 7.4
7 F l u e P r e p a r a t i o n
Diagram 7.5
FLUE
TERMINAL
WALL
SLEEVE
AIR
DUCT
OUTSIDE
WALL FACE
58
Diagram 7.6
130 DIA
CORE
DRILLED
HOLE
FOAM
SEAL
AIR DUCT/
TERMINAL
FOAM
SEAL
AIR DUCT/
TERMINAL
FOAM
SEAL
Q
10mm
Q minus 55mm
7.5 Wall Thickness up to 300mm
Fit the self adhesive seal provided in the loose items
pack around the air duct/terminal at the position shown
in diagram 7.4.
7.6 Wall Thickness 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, see diagram 7.5.
If the boiler is not to be fitted for some time cover the
hole.
7.7 Internal Flue Assembly
Place the flue assembly into the flue hole to make sure
that the flue terminal is correctly positioned and is the
correct distance from the outside wall face, see diagram
7.6 and the appropriate diagram 7.1 or 7.2.
7.8 External Flue Assembly
Remove the flue elbow from the air/terminal duct and
the flue duct.
From outside place the flue/air duct assembly into and
through the wall sleeve.
4569
4570
0181M

Supplied By www.heating spares.co Tel. [phone]
17 220674B
0182M
8 G a s a n d W a t e r C o n n e c t i o n s
Diagram 8.1
Diagram 8.2
EXPANSION
VESSEL POSITION
20mm 46mm
320
DOMESTIC
WATER CENTRAL HEATING
NOTE:
Keep any pipework
clear of shaded area
80
90
140
SLOT (CLOSED) DRAIN
POINT SLOT (CLOSED)
GAS
SERVICE
COCK
‘NOTCH’ MARKING POSITION OF
SAFETY VALVE DISCHARGE
HEATING
FLOW HEATING RETURN DOMESTIC
HOT WATER
OUT
63
2297
DOMESTIC
COLD WATER
SUPPLY IN
BOILER
MOUNTING
FRAME
8.1 Gas Connection
The gas supply can be connected from below or through
the wall at the rear of the boiler, see diagram 8.1 for
position.
Refer also to Section 1.7.
Make the gas supply connection to the gas service cock.
Slacken or remove the clip, as desired, whilst making the
connection. Do no subject the gas service cock to heat.
8.2 Water Connections
Provision is made for the water connections to be made
from below or through an internal wall at the rear of the
boiler, see diagram 8.1 for position.
Provision is made for the domestic hot water outlet and
heating flow and return pipes to be connected from
above, if desired, passing down either side of the boiler,
see diagram 8.2 for clearances. Take care that any
pipework connected from above, within the boiler
mounting frame will clear the expansion vessels.
Flush out the domestic hot water and the heating systems
before connecting to the boiler.
Make the connections to the domestic hot water and
heating systems by way of the isolating valves, see
diagram 8.1.
Slacken or remove the clips, as desired, while making
the connections. Do not subject any of the isolating
valves to heat.
Make sure that the drain points on the isolating valves
are positioned towards the front of the boiler, also that
the drain and operating screw heads are accessible.
8.3 Safety Valve Discharge
WARNING. It must not discharge above an entrance or
window or any type of public access area.
A short discharge pipe is supplied loose with the boiler,
which when fitted to the safety valve, will end below the
boiler at the mark between the cold water inlet and the
heating flow, for position and dimension see diagram
8.1.
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 so that any discharge of water, possibly boiling,
or steam cannot create any danger to persons, damage to
property or external electrical components and wiring.
Note. To make future servicing easier it is advisable to
use a compression type fitting to extend the discharge
pipe.

Supplied By www.heating spares.co Tel. [phone]
18
220674B
9 E l e c t r i c a l C o n n e c t i o n s
JUNCTION
BOX
3 AMP
FUSE
LN
240V~50Hz
PERMANENT MAINS
SUPPLY
240V~50Hz
ROOM STAT. 240V~50Hz FROST STAT.
TO BOILER
RED LINK.
REMOVE WHEN
CONNECTING
SYSTEM CONTROLS
5 POLE CONNECTOR ON
MOUNTING FRAME
240V~50Hz
POTENTIAL
FROST STAT.
240V~50Hz
POTENTIAL
ROOM STAT.
(3) (L) (N) (2) (1)
JUNCTION
BOX
3 AMP
FUSE
LN
240V~50Hz
PERMANENT MAINS
SUPPLY
240V~50Hz
ROOM STAT. USED AS LINK
240V~50Hz
FROST STAT.
TO BOILER
RED LINK.
REMOVE WHEN
CONNECTING
SYSTEM CONTROLS
5 POLE CONNECTOR ON
MOUNTING FRAME
MAINS
POTENTIAL
FROST STAT.
MAINS
POTENTIAL
ROOM STAT.
(3) (L) (N) (2) (1)
JUNCTION
BOX
3 AMP
FUSE
LN
240V~50Hz
PERMANENT MAINS
SUPPLY
240V~50Hz
FROST STAT. NO ROOM STAT.
TO BOILER
RED
LINK
5 POLE CONNECTOR ON
MOUNTING FRAME
MAINS
POTENTIAL
FROST STAT.
(3) (L) (N) (2) (1)
3 AMP
FUSE
LN
240V~50Hz
PERMANENT MAINS
SUPPLY
POTENTIAL
FREE ROOM STAT. NO FROST STAT.
TO BOILER
RED LINK.
REMOVE WHEN
CONNECTING
SYSTEM CONTROLS
5 POLE CONNECTOR ON
MOUNTING FRAME
POTENTIAL FREE
ROOM STAT.
(3) (L) (N) (2) (1)
DOUBLE
POLE
ISOLATOR
JUNCTION
BOX
3 AMP
FUSE
LN
240V~50Hz
PERMANENT MAINS
SUPPLY
240V~50Hz ROOM STAT. NO FROST STAT.
TO BOILER
RED LINK.
REMOVE WHEN
CONNECTING
SYSTEM CONTROLS
5 POLE CONNECTOR ON
MOUNTING FRAME
MAINS POTENTIAL
ROOM STAT.
(3) (L) (N) (2) (1)
5 POLE CONNECTOR ON
MOUNTING FRAME
TO BOILER
RED LINK.
REMOVE WHEN
CONNECTING ANY
HEATING SYSTEM
CONTROLS
TIME
CONTROL
CLOCK
SWITCH
CONTACTS
(3) (L) (N) (E) (2) (1)
JUNCTION
BOX
3 AMP
FUSE
ROOM
THERMOSTAT
FROST
THERMOSTAT
LNE
240V~50Hz
PERMANENT
MAINS SUPPLY
ELECTRICITY SUPPLY CONNECTIONS
DOUBLE
POLE
ISOLATOR
DOUBLE
POLE
ISOLATOR
DOUBLE
POLE
ISOLATOR
DOUBLE
POLE
ISOLATOR
DOUBLE
POLE
ISOLATOR
(E)
(E)
(E)
(E)
(E)
E
E
E
E
E
0060M
INTEGRAL CLOCK
INTEGRAL CLOCK
INTEGRAL CLOCK
INTEGRAL CLOCK
EXTERNAL CLOCK INTEGRAL CLOCK
Diagram 9.1

Supplied By www.heating spares.co Tel. [phone]
19 220674B
9 E l e c t r i c a l C o n n e c t i o n s
Diagram 9.2
MAINS
CABLE
CABLE
CLAMP
LNE2
3
1
COVER
SCREW (2)
RED LINK
Remove when
connecting any
heating system
controls.
9.1 Supply Cable Connection
The boiler requires a permanent mains supply through an
isolator which must also isolate any heating system
controls, see diagram 9.1.
Any heating system controls must not interrupt the
permanent mains supply to the boiler.
Remove the electrical connector from the loose items
pack.
Remove the two screws and cover from the connector,
see diagram 9.2.
Using PVC cable of suitable length and rating as stated
in Section 1.8, connect the mains supply cable to the
appropriate terminals of the connector, see diagram 9.1.
Standard colours are, Brown - Live; Blue - Neutral;
Green and Yellow - Earth.
The mains cable outer insulation must not be cut back
external to the plug, see diagram 9.2.
Make the earth cable of a greater length so that if the
cable is strained the earth would be the last to become
disconnected.
CAUTION. It is essential that the polarity is correct.
9.2 Heating System Controls
It is recommended that the heating system is controlled
by a Time-switch and Room Thermostat, (controls may
be mains, low voltage or potential free), or by
thermostatic radiator valves.
If electrical controls are not being used, DO NOT
REMOVE the red link between terminals 1 and 2.
If electrical controls are being used the red link between
terminals 1 and 2 should be removed and the heating
controls connected in series.
The mains cable outer insulation must not be cut back
external to the plug.
9.3 Clock/Timer Kit
An internal clock/timer kit can be supplied, refer to the
literature supplied with the kit.
9.4 Frost Thermostat
If the installation requires protection by a “frost
thermostat”, connect a single pole type, to the
appropriate terminals of the connector.
9.5 Cable and Connector Securing
After completing all the connections to the boiler, secure
the cable(s) with the cover, using the two screws
previously removed, see diagram 9.2.
2643

Supplied By www.heating spares.co Tel. [phone]
20
220674B
1 0 B o i l e r F i x i n g
Diagram 10.1
Diagram 10.2
0204M
WALL
SLEEVE WALL FACE
FLUE
ELBOW
FLUE DUCT
AIR DUCT/
TERMINAL
FLUE
ELBOW
FLUE DUCT
AIR DUCT/
TERMINAL
FLUE
DUCT/
ELBOW
AIR DUCT/
TERMINAL
3mm Drill
Sealing
Tape
FLUE ELBOW/
AIR DUCT
SECURING
SCREW (4)
BOILER SECURING
SCREW (2)
10.1 Mounting the Boiler
After installing the flue, boiler mounting frame, gas,
domestic and heating systems, 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, fully push the boiler back to
the mounting frame, locating the studs into the clips,
then loosely fit the two boiler securing screws at the top,
see diagram 10.1.
10.2 Internal Flue Fixing
Fit gasket to flue elbow.
Secure the flue assembly to the boiler, see diagram 10.1.
Fit the fan to the flue elbow spigot making sure the fan
sealing ring is fitted correctly and secure with the
previously removed screws.
Secure the flue collector thumb screws.
10.3. External Flue Fixing
Fit gasket to flue elbow.
Locate flue elbow onto the boiler.
Fit the fan to the flue elbow spigot making sure the fan
sealing ring is fitted correctly and secure with the
previously removed screws.
Secure the flue collector thumb screws.
Pull the flue/air duct(s) forward and engage onto the flue
elbow, see diagram 10.2. Check the wall face to
terminal dimension, see diagram 7.6.
Push the air duct back into the wall sleeve, whilst
holding the flue duct onto the flue elbow, then secure the
flue duct to the elbow, see diagram 10.2.
Pull the air duct back into engagement with the flue
elbow and secure/seal.
10.4 Gas and Water Connections
Locate the boiler water pipes into the isolation valves
and the gas service into the gas cock union halves.
Make the compression joint on the isolating valves and
join the gas service cock union. Secure all of the valves
and gas service cock with the clips.
10.5 Boiler Securing
Secure the boiler by tightening the two boiler securing
screws at the top.
4571