Glowworm swift flow 75e Operating manual

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221422A.10.98
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]
Instructions for Use
Installation and Servicing
Tobeleftwiththeuser
This is a Cat I2H Appliance
5226
Fanned Flue Combination Boiler
With Honeywell gas control
G.C. No. 47 313 16
75e
All replacement parts
All labour charges
All call-out charges
Guarantee Registration
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0181 380 2555
Thank you for installing a new Glow-worm appliance in your home.
Glow-worm appliances' are manufactured to the very highest standard so we are pleased
to offer our customers' a Comprehensive First Year Guarantee.
In the center pages are to be found your Guarantee Registration Card, which we recommend you complete and
return as soon as possible.
If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer
Service number 01773 828100.
Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:
The instructions consist of three parts, User, Installation and Servicing Instructions, which include 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.
❏
✔
❏
✔
❏
✔

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Testing and Certification
This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler,
without permission, in writing, from Hepworth Heating Ltd.
Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the
current issue of the Statutory Requirements, see Section 1.4.
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 0087.
Product/production certified by: Notified body 0087.
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.
Substances Hazardous to Health
The adhesives and sealants used in this appliance are cured and give no known hazard in this state.
INSULATION PADS/CERAMIC FIBRE, GLASSYARN, MINERAL WOOL
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.
Important Information
Introduction 3
Clock Settings 4
Lighting the Boiler 5
General Data 1 6
Boiler Position 2 8
Flue and Ventilation 3 9
Heating System 4 11
Domestic Hot Water System 5 14
Installation Preparation 6 14
Flue Preparation 7 16
Gas and Water Connections 8 17
Electrical Connections 9 18
Boiler Fixing 10 20
Commissioning 11 21
General Data 1 25
Servicing 2 26
Fault Finding 3 27
Replacement Parts 4 34
Spare Parts 5 46
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
SERVICING
INSTRUCTIONS

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3221422A
Introduction
Pleasereadtheseinstructionsandfollowthemcarefullyforthe
safe and economical use of your Combination boiler.
This boiler must have been installed by a competent person in
accordancewiththerulesinforceinthecountriesofdestination.
Once the pilot has been lit and the controls set, the boiler is
automatic in operation.
The Swift-flow combination boiler is able to provide room
heating as part of a central heating system and domestic hot
water direct from the cold water supply, without the need for
secondary storage.
The boiler can be fitted with one of two makes of clock, which
look like this:-
IMPORTANT NOTICE:
This boiler is for use only on G20 gas.
Gas Leak or Fault
Ifagasleakorfaultexistsorissuspected,turntheboileroffand
consult your local gas company or your local installation/
servicing company.
Domestic Hot Water Temperature
NOTE. Themainswatertemperatureinthewinterislowerthan
in the summer.
Thewatertemperaturecanbeincreasedorreducedbyadjusting
the flow rate at the hot water draw off tap.
Boilers Installed in Compartments
Iftheboiler has been fitted into acompartmentor cupboard, do
not obstruct the compartment air supply vents.
Do not use the compartment for storage.
Electrical Supply
WARNING. The boiler must be earthed.
The boiler must be connected to a 230V~50Hz permanent
supply.
Connection of the whole electrical system of the boiler and any
heatingsystemcontrolstotheelectricalsupply,mustbethrough
one common isolator.
Isolation should preferably be by a double pole switched fused
spurbox. The fused spur box should be readily accessible and
preferably adjacent to the appliance. It should be identified as
to its use.
Alternatively a fused 3A 3 pin plug and shuttered unswitched
socket may be used.
Thecoloursofthreecoreflexiblecableare,blue-neutral,brown
- live, green and yellow - earth.
As the markings on your plug may not correspond with these
colours continue as follows:-
The wire coloured blue must be connected to the terminal
marked “N” or “Black”.
The wire coloured brown must be connected to the terminal
marked “L” or “Red”.
The wire coloured green and yellow must be connected to the
terminal marked “E” or “Green” or the earth symbol .
PVC flexible cable having a conductor size of 0.75mm2(24/
0.20mm)mustbeusedwithintheboilercasingtoconnecttothe
boiler.
Electrical Supply Failure
The boiler will not work without an electrical supply.
Normaloperationoftheboilershouldresumewhentheelectrical
supply is restored.
Note. The boiler safety cutoff may have operated, please refer
to the following section to reset.
Reset any external controls, to resume normal operation of the
central heating.
Thedigitaltimer,hasalithiumbatterybackupandwillnot need
resetting.
Boiler Safety Cutoff Reset Button
Theboilerisfittedwithasafetycutoffdevicetopreventdamage
through overheating.
Should the main burner go out during a demand the red neon
on the Reset Button will light.
In certain circumstances the red neon light may not come on,
duetonosystemdemand. Itissuggestedthatahotwaterdraw
off tap be opened to create a demand, the neon should then
come on.
Allow the boiler and system to cool down waiting at least a
minimum of four minutes before pressing the Reset button.
If the problem persists, turn the boiler off and consult the local
gas company or your installation/ servicing company.
6509
Clock / Timer
Digital timer Electro / mechanical
clock / timer
Instructions for Use

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Setting Timed Programmes
With the clock set to the correct time, see SETTING THE
CLOCK paragraphs 1-4, and then continue as follows:
1. Set RUN switch to P , the display will indicate
the 1st (ON) preset programme and the symbol .
2. Set day of week to be programmed by pressing the
DAY button.
Note: The days can be selected individually or as
groups:
Mon-Fri., Mon-Sat., Mon-Sun., Sat/Sun.
An arrow will be displayed under the day
or days selected.
3. Set time of day by pressing the buttons HR and MIN.
4. Press button P to confirm programmes, the
display will indicate the 2nd (OFF) preset
programme and subsequently, 3rd, 4th, 5th, 6th,
7th, 8th.
5. Repeat procedures 2, 3 and 4 until desired
programmes are set.
Note. It is not a requirement to use the 8 on/off
programmes.
6. Set the RUN switch the central position, your
appliance will now operate at the programmed times.
General Notes.
With the AUTO switch in the I position the central
heating will operated constantly ON.
With the AUTO switch in the O position the central
heating will not operate.
Soft Override button indicated by the
symbol , this function will override the
current central heating programme for the
next available.
ON time programmes are indicated by the symbol .
Setting the Clock
1. With both AUTO and RUN switches set to the central
position, press R reset button, the display will flash.
2. Set RUN switch to .
3. Set day of week by pressing button DAY.
4. Set time of day by pressing buttons HR and MIN.
5. Set RUN switch to the central position, colon will flash, this
indicates the clock is set.
With the clock set, the factory preset programme shown below
will operate.
Setting Instructions for Electro/mechanical
Clock - if fitted
This clock has a twenty four hour dial, that is, 1pm is 13.
To set the time, turn the whole face clockwise until the pointer
is against the time of day.
To set any “Off” time, push the tappets outwards.
To set any “On” time, push the tappets inwards.
Timecan be set either “On” or “Off” in fifteen minute segments.
Note. Theclocksuppliedcouldbefittedwithanoverridedevice,
see diagram 1, which switches the clock programme “On” or
“Off” permanently.
Theswitch willneedtobe repositioned toresumeprogrammed
working.
0
I
12
13
14
15
16
17
18
19
20
21
22
23
24
1
2
3
4
5
6
7
8
9
10
11
Diagram 1
OVERRIDE
SWITCH
POINTER
TAPPETS
CLOCK FACE
CONSTANT OFF
PROGRAMMED
CONSTANT ON
0
I
4956
Setting Instructions for the 7 Day Digital
Clock/Timer
This is a 24 hour clock/timer, that is 1pm is 13:00, and has 8
“ON” and 8 “OFF” daily switching actions.
It is fitted with a lithium battery back up which protects the
programme in the event of an electrical failure. The battery
should have a life of several years.
Instructions for Use
Diagram 2
5673
AUTO RUN
MT WThFSSu
P
DAY HR MIN
P
R
I
MON/FRI
ON - 06:30
OFF - 08:30
ON - 16:30
OFF - 22:30
SAT/SUN
ON - 07:00
OFF - 09:00
ON - 16:00
OFF - 23:00

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Diagram 3
6088
GAS SERVICE
COCK HOT WATER
OUT
COLD WATER
SUPPLY IN
HEATING
FLOW HEATING
RETURN
SLOT (OPEN)
SAFETY
VALVE
DISCHARGE
DRAIN
POINT
SLOT (OPEN)
6625
SWITCH
ON
CENTRAL HEATING
SELECTOR SWITCH 'C' CONTROL
RESET
BUTTON
SWITCH
OFF
5044
PRESSURE
GAUGE ‘A’
Diagram 4
To Light the Boiler
1. Check that all five isolating valves are open, the slots in line
with the length of the valve, see diagram 3.
2. Openthedoor,bypushingatthesideoppositeto thehinge.
3. CAUTION. A sealed pressurised system must be filled and
pressurised by a competent person.
Only operate the boiler when you are sure that the system has
been filled and pressurised. Check this by looking at the
pressuregauge“A”,diagram 4,itshouldread0.7barminimum.
4. Check reset button neon, refer to previous instructions on
page 3.
5. Open a hot water tap, check that water flows, then close it.
6. Ifyou areinany doubtabouttheboiler beingfilledwith water
contact your installation/servicing company or the local gas
company.
7. Check that the electrical supply to the boiler is ON at the
external isolator.
8. Setswitch “C”, clock/timer (if fitted) and any remote controls
as required.
Close the door.
Incertain circumstances, a surge inwater pressure may cause
the appliance to operate momentarily, this will be indicated by
the pump starting and the fan speed increasing. This is quite
normal.
Central Heating Selector Switch
For central heating set switch “C” to “On” as shown in diagram
4. The main burner will light.
When the heating is controlled by a room thermostat and/or a
time switch, switch “C” must be set “On”.
Ifahotwatertapis openedwhiletheboilerisonfor heating,the
burnerflamewillincreaseinsize andprioritywillbegiventohot
water.
When the hot water tap is closed, the main burner flames will
decreasein sizebutwillremain alight untiltheboilercontrols or
any heating controls switch it off.
Which ever position switch “C” is in domestic hot water will be
available.
To Turn the Central Heating Off
To turn the heating off for short periods, set switch “C” to “Off”
as shown in diagram 4.
To turn on again set switch “On”, see diagram 4.
To Turn the Boiler Off
Toturntheboileroff,isolatetheboilerfromtheelectricalsupply.
To turn on again following the operating instructions.
Domestic Hot Water Temperature
NOTE. Themainswatertemperatureinthewinterislowerthan
in the summer.
Thewatertemperaturecanbeincreasedorreducedbyadjusting
the flow rate at the hot water draw off.
Maintenance and Servicing
To ensure the continued efficient and safe operation of the
appliance it is recommended that it is checked and serviced as
necessary at regular intervals. The frequency of servicing will
depend upon the particular installation conditions and usage,
but in general once a year should be enough.
If this appliance is installed in a rented property there is a duty
of care imposed on the owner of the property by the current
issue of the Gas Safety (Installation and Use) Regulations,
Section 35.
Servicing/maintenance should be carried out by a competent
person in accordance with the rules in force in the countries of
destination.
To obtain service, please call your installer or Heatcall (Glow-
worm’s own service organisation) using the telephone number
behind the controls access door, see diagram 4.
Instructions for Use

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221422A
1 General
Instructions for Use
Clearances
The boiler requires a clearance in front, below and at the sides
ofthecasingforsafety,servicingandmaintenanceaccess,see
diagram 2.1.
Protection Against Freezing
Iftheboileristobeoutofuseforanylongperiodsduringsevere
weather, it is recommended that the whole system, including
the combination boiler, should be drained to avoid the risk of
freezing.
Ifindoubt,contactyouinstallation/servicingcompanyforadvice.
Draining and Filling
CAUTION. This boiler works in a pressurised system which
must only be drained, refilled and pressurised by a competent
person.
Note: Ifthepressuregaugeindicatesalossofsystempressure,
that is, less than 0.7bar, YOU MUST CONTACT YOUR
INSTALLER.
Pressure Relief Safety Valve
CAUTION. Apressure relief safety valve anddischargepipeis
fittedtotheboiler. Thisvalvemustnotbetouched. Shouldthere
be any discharge from the pipe, turn the boiler off, isolate from
the electrical supply and contact your installation/servicing
company.
Cleaning
WARNING. Thisappliancecontainsmetalparts(components)
and care should be taken when handling and cleaning with
particular regard to edges.
The boiler casing can be cleaned using a mild liquid detergent
with a damp cloth, then a dry cloth to polish.
Do not use any form of abrasive or solvent cleaner as you may
damage the paint work
Boiler Casing
CAUTION. Do not remove or adjust the casing in any way, as
incorrect fitting may result in incorrect operation or failure to
operate at all. If in doubt seek advice from the local gas
company or your installation/servicing company.
Replacement Parts
Ifreplacement parts are required apply to yourlocal supplier or
British Gas.
Please quote the name of the appliance.
ALL DIMENSIONS in MILLIMETRES
KEY:
15mm COMPRESSION
DOMESTIC WATER Rc
1/2
(
1/2
in. BSPT)
GAS CONNECTION
22mm COMPRESSION
CENTRAL HEATING
Diagram 1.1
SAFETY
VALVE
DISCHARGE
63
117
331
168
101
66 107 107 66 2.5
25
2257
2.5
25
82mm L
C
MOUNTING
WALL
2257A
L
C
450
63
783

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7221422A
1 General
1.1 Installation
Materials and equipment should be fit for their purpose and of
suitable quality and workmanship.
1.2 Important Notice
This boiler is for use only on natural gas, G20.
1.3 Sheet Metal Parts
WARNING. Wheninstalling orservicingthisboiler care should
betakenwhenhandlingtheedges ofsheetmetalpartstoavoid
any possibility of personal injury.
1.4 Requirements
Theinstallationofthisboilermustbecarriedoutbyacompetent
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
1.7 Gas Supply
Thegasinstallationshallbeinaccordancewiththerulesinforce
in the countries of destination.
The supply from the governed meter must be of adequate size
toprovideasteadyinletworkingpressureof20mbar(8inwg)at
the boiler.
1.8 Electrical Supply
WARNING. This boiler must be earthed.
All system components shall be of an approved type.
The electrical installation shall be in accordance with the rules
in force in the countries of destination.
Connection of the whole electrical system of the boiler and any
heatingsystemcontrolstotheelectricalsupply,mustbethrough
one common isolator.
Isolation should be by a double pole switched fused spur box,
havingaminimumcontactseparationof3mmineachpole. The
fused spur box should be readily accessible and preferably
adjacent to the appliance.It should be identified as to its use.
Alternatively, a fused 3A 3pin plug and unswitched socket may
beused,providedtheyarenotusedinaroomcontainingabath
or shower.
The mains supply cable and other cables connected to the
boiler must be the PVC flexible type of at least 0.75mm2 (24/
0.20mm) .
C.H.
MAX D.H.W.
MAX MIN
NOMINAL kW
HEAT
INPUT(NETT) Btu/h
NOMINAL kW
HEAT
OUTPUT Btu/h
BURNER mbar
PRESSURE in.wg
APPROX. m3/h
GAS RATE ft3/h
TABLE 1
75e 18.2
62,000
27.5
93,750
10.7
36,576
16.12
55,000
22.0
75,000
8.79
30000
15.6
6.3
8.0
3.4 2.4 1.0
2.0
69.5 2.6 92.5 1.2
42.1
Diagram 1.2
WATER
THROTTLE
MINI
EXPANSION
VESSEL
HEAT EXCHANGER
MAIN BURNER
PRESSURE
SWITCH
D.H.W.
COLD
INLET
C.H.
FLOW
AUTOMATIC
AIR VENT
EXPANSION
VESSEL
FLOW
SWITCH
FANNED
FLUE
SPARK
ELECTRODE
5228
PUMP
GAS
VALVE
SAFETY
VALVE
SAFETY
VALVE DISCHARGE
GAS
SUPPLY C.H.
RETURN D.H.W. HOT
OUTLET

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Lift Weight 37.0kg (81.4lb)
Total Weight 50.4kg (111lb)
●Gas connection Rc1/2(
1/
2in 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)
2267
55
5
DIMENSIONS
IN MILLIMETRES
5
Diagram 2.1
5
800
INCREASE TO 25MM CLEARANCE
FROM COMBUSTIBLE MATERIAL
150
150
2.1 Location
This boiler must be installed in accordance with the rules in
force in the countries of destination.
This boiler is not suitable for fitting outside.
Any electrical switch 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
Section 1, “Data”.
If the location of the boiler or any part of the system is subject
to severe cold weather conditions, it is recommended that a
frost thermostat is fitted. Any part of the system that may be
vulnerable to freezing must be protected.
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, Cupboard/Compartment Ventilation.
2.2 Clearances
The boiler should be positioned so that at least the minimum
operationalandservicingclearancesareprovided,seediagram
2.1. Additionalclearancesmayberequiredaroundtheboilerfor
installation.
❋D.H.W 0.5 to 10bar
working pressure (7.25 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 230V~50Hz
Electrical rating 154W fused 3A
Internal Fuse rating 1) Type T2A
2) Type T630mA
■For larger systems use an additional expansion vessel, see Section 4.
❋Boiler starts at an inlet pressure of 0.5bar but requires 0.8bar for maximum output.
●Ball valves are fitted in water and gas connections, plus a drain point on all water connections.
TABLE 2
2 Boiler Position
1 General

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WALL THICKNESS 'X': 75 TO 400mm
DISTANCE 'Y': 80 TO 343mm
1m DISTANCE 'Y': 80 TO 833mm
2m DISTANCE 'Y': 80 TO 1833mm
3m DISTANCE 'Y': 80 TO 2833mm
1m DISTANCE 'X': 75 TO 898mm
2m DISTANCE 'X': 75 TO 1898mm
3m DISTANCE 'X': 75 TO 2890mm
3 Flue andVentilation
Diagram 3.1
Diagram 3.2
2309
Diagram 3.4
SIDE FLUE - STANDARD
Left or Right SIDE FLUE - LONG
Left or Right
REAR FLUE - STANDARD
'X'
'Y'
'Y'
2311
2308
Diagram 3.3
2310
REAR FLUE - LONG
'X'
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
Theairandflueductingconnecttothetopoftheboilerusingthe
elbowwhichcanbepositionedinoneofthreepossibledirections:
Rearward, left or right.
Thestandardflueisabletoprovidetheductlengthrangeshown
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 and 3metre flue system and elbow/ terminal kit must be
used and can be supplied.
This is able to provide the duct length range shown in diagram
3.3 for rear flue or diagram 3.4 for a side flue.
A Flue Bend Kit or Vertical Flue Kit can be supplied with
instructions.
To make a neat finish to the flue outlet a flue collar kit, part No.
443286, with instructions, is available.
Theuse of this collar will mean that the flue lengths will need to
be altered, full instructions are given in the kit.
3.3 Terminal Position
The minimum acceptable siting dimensions for the terminal
fromobstructions,otherterminalsandventilationopeningsare
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.
Carportorsimilarextensionsofaroofonly,orroofandonewall,
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
comprisesofaroofandtwoormorewallsseekadvicefrom the
local gas undertaking before installing the boiler.
Ifthe terminal is fitted within 600mm belowplastic 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.
3.4 Timber Frame Buildings
If the boiler is to be installed in a timber frame building seek
advicefromthelocalgasundertakingorfromHepworthHeating
Ltd.

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4783
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
MINIMUM SITING DIMENSIONS FOR
FANNED FLUE TERMINALS
POSITION
mm
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 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
2816
Diagram 3.5
Low Vent 248cm238in2124cm219in2
High Vent 248cm238in2124cm219in2
TABLE 2 75e
Position Air from Air Direct
of Room or from
Air Vent Internal space Outside
3 Flue andVentilation
3.5 Terminal Guard
A terminal guard is required if persons could come into contact
with the terminal or the terminal could be subject to damage.
If a terminal guard is required, it must be positioned to provide
aminimumof50mmclearancefromanypartoftheterminaland
be central over the terminal.
The guard should be similar to that shown in diagram 3.5 and
can be bought from:
Tower Flue Components Ltd.
Morley Road
Tonbridge
Kent
TN9 1RA
their type K3
3.6 Room Ventilation
Ventilation must be provided in accordance with the rules in
forcein the countries of destination. The boiler is room sealed,
sowhere the boiler isfitted in a roomor space, a permanentair
vent is not required.
3.7 Cupboard/Compartment Ventilation
If the boiler is to be fitted in a cupboard or compartment,
permanent high and low level air vents must be provided for
ventilation. The vents must have at least the effective areas
shown in Table 2.

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AVAILABLE PUMP HEAD
SYSTEM DIFFERENTIAL TEMPERATURE
SYSTEM HEATING LOAD
*
0
5
10
15
17
20
11
40
35
30.6
25
19.8
15
10
5
0
F
0
C
0
0
15
30
40
50
60
0
1
2
3
5
10
16
14
4
10
12
5
FEET
4.5
4.03.53.0
2.5 5.0 GALLONS/Min
LITRES/Min
FLOW RATE
18
1715
13
11 19 20 22 23
Btu/h x
1000 kW
21
ACCEPTABLE
DIFFERENTIAL
RANGE
*
P
U
M
P
C
U
R
V
E
-
S
E
T
T
I
N
G
3
P
U
M
P
C
U
R
V
E
-
S
E
T
T
I
N
G
2
REMAINING CONVEYING CAPACITY OF PUMP
SHOWING RELATIVE SYSTEM DIFFERENTIAL AT
VARIOUS SYSTEM HEATING LOADS.
M
AVAILABLE PUMP HEAD
SYSTEM DIFFERENTIAL TEMPERATURE
SYSTEM HEATING LOAD
*
0
5
10
15
17
20
11
40
35
30.6
25
19.8
15
10
5
0
F
0
C
0
0
15
30
40
50
60
0
1
2
3
5
10
16
14
4
10
12
5
FEET
4.5
4.03.53.0
2.5 5.0 GALLONS/Min
LITRES/Min
FLOW RATE
18
1715
13
11 19 20 22 23
21
ACCEPTABLE
DIFFERENTIAL
RANGE
*
P
U
M
P
C
U
R
V
E
-
S
E
T
T
I
N
G
2
/
W
I
L
O
S
E
T
T
I
N
G
REMAINING CONVEYING CAPACITY OF PUMP
SHOWING RELATIVE SYSTEM DIFFERENTIAL AT
VARIOUS SYSTEM HEATING LOADS.
M
- Setting 2- Setting 1
P
U
M
P
C
U
R
V
E
-
S
E
T
T
I
N
G
1
/
W
I
L
O
S
E
T
T
I
N
G
Btu/h x
1000 kW
Diagram 4.1
Diagram 4.1A
GRUNDFOS
WILO
4 Heating System

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4.1 General Notes
The boiler is intended for use in a sealed system only.
4.2 Safety Valve
The safety valve is an integral part of the boiler.
It cannot be adjusted but has a manual test device.
4.3 Pressure Gauge
A pressure gauge is incorporated into the boiler to indicate the
system pressure.
The gauge has a cold fill set pointer.
4.4 Pump
The circulation pump is integral with the boiler.
The remaining circulating pressure head available from the
boilerisshownindiagram4.1,Grundfosordiagram4.1A,Glow-
worm Wilo.
4.5 Expansion Vessel
The boiler has an integral expansion vessel with a capacity of
8Litres, (1.76gall). If the system water content exceeds the
maximum quoted in Section 1, Data, an additional vessel
shouldbeconnectedintothesystemascloseaspossibletothe
centralheatingreturnconnectionoftheboiler,seediagram4.2.
The pressure shall not be less that the static head at the point
of connection, that is, the height of the top point of the system
above the expansion vessel.
4.6 Flow Rate
A valve must be incorporated in the main flow or return of the
system, valve “A” shown in the flow diagram 4.2. This valve
must be lockable and positioned so that inadvertent closure or
unauthorisedinterferenceisnotpossible. Thedesigndifferential
canbebetween11°C(20°F)and17°C(30°F),dependentupon
the system resistance and the available pump head.
Grundfos Pump
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.
Tousediagram4.1startwiththerequired heatingsystemload.
Intheexampleshownthe80emaximumboileroutputhasbeen
chosen, 17.6kW (60,000Btu/h).
Draw a horizontal line from the required system differential
temperature axis to intersect the curve.
In the example 11°C (19.8°F) 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
example1.9m(6ft4in)isavailable.Agreaterpumpheadcanbe
achievedbychoosingahighersystemdifferentialtemperature,
up to a maximum of 4.0m (13ft) at a system differential of 17°C
(30.6°F). Thesystemmustbedesignedsuchthattheavailable
pump head is not exceeded.
If the heating system load is less than 13.2kW (45,000Btu/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 Heating System
Glow-worm Wilo Pump
The pump adjuster should normally be left at maximum (2) but
in some cases it is permissible to adjust to a lower setting (1),
see diagram 4.1A.
To use diagram 4.1A start with the required heating system
load.
Intheexampleshownthe80e maximumboileroutputhasbeen
chosen, 17.6kW (60,000Btu/h).
Draw a horizontal line from the required system differential
temperature axis to intersect the curve. In the example 11°C
(19.8°F) has been chosen,shown . At the point of
intersection draw a vertical line to cross the pump curve. From
thispointdrawafurtherhorizontallinetodeterminetheavailable
pumphead. Intheexample1.9m(6ft3in)isavailable. Agreater
pump head can be achieved by choosing a higher system
differential temperature, up to a maximum of 4.0m (13ft) at a
system differential of 17°C (30.6°F). The system must be
designed such that the available pump head is not exceeded.
If the heating system load is less than 13.2kW (45,000Btu/h)
then it is permissible to adjust the pump setting to (1),
shown . This results in an available pump head
of 4.2m (13ft9in). This is the maximum than can be achieved
with the pump at this setting.
4.7 Bypass
Itisessentialthatabypassisfittedinallinstallations,22mmo.d.
minimum. The bypass must have a lockable valve “B” in
diagram 4.2, incorporated in a position so that inadvertent
closure or unauthorised interference 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
systemusingamakeupbottlemountedinapositionhigherthan
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

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4 Heating System
Diagram 4.3
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
3132
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.
NOTE:Itisimportantthatfittingsusedforconnectiontopotable
water comply with the water undertakers requirements.
4.10 Corrosion Inhibitor
If an inhibitor is to be used in the system, contact the inhibitor
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,
thenthoroughly cleaning out before fittingthe boiler whether or
not adding an inhibitor.
4.11 Draining
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.
2818
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)

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5 Domestic Hot Water System
5.1 General
Thedomestic hot water service mustbeinaccordancewiththe
rules in force in the countries of destination.
5.2 Water Pressure
For the minimum and maximum working pressures of the
domestichotwatercircuitoftheboilerrefertoSection1.6Data.
If the cold water supply pressure exceeds the maximum, a
governor 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”, more than 200mg/litre, it is
recommended that a proprietary scale reducer is fitted in the
coldwatersupplytotheboiler. Checkthetotalwater“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
scalereducer. Fortherelativepositionofthescalereducerand
pressurereducingvalve,ifrequired,refertothemanufacturer’s
instructions.
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.
Remove the cover of the inner case, secured with four screws,
see diagram 6.2.
Disconnect the gas service cock union and the front unions of
the isolation valves, see diagram 6.3.
Slightlyloosentheclipsofthegasservicecockandtheisolating
valves.
Remove the two boiler securing screws then remove the boiler
fromthemountingframe,bypullingthestudsfromtheclipsand
unhooking it at the top.
6.2 Marking
Theboilermountingframeisthesamewidthastheboilerbutthe
flue connection sticks out above it.
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
forwardsandthattheframetopishorizontal,thenmarkthefour
wall fixing points through the holes in the two horizontal straps.
6 Installation Preparation
OUTER CASE
SECURING SCREW (2)
( IF CLOCK FITTED (4) )
Diagram 6.1
6625
CENTRAL HEATING
SELECTOR SWITCH
DOOR
RESET
SWITCH + NEON
OUTER CASE
Position the flue template on the wall, the arrow points on the
centres of the two upper fixing points previously marked, see
diagram 6.4 which also shows dimensions.
Forrearflue,marktherearfluepositionasrequired,centreand/
or diameter.
CLOCKTIMER
IF FITTED

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Diagram 6.4
2304
FLUE
CENTRE
LINE
CORNER
(Left Flue)
CORNER
(Right Flue)
115Dia.
168 168
0176M
300
TOP OF
BOILER
115Dia.
MIN.
CLEARANCE
584 480 FLUE
TEMPLATE
(Cut from
carton top
inner flap)
BOILER
MOUNTING FRAME
FIXING POINTS
FLUE
CENTRELINE
104
87
C
L
C
L
6 Installation Preparation
Diagram 6.3
INNER
CASE
COVER
SECURING
SCREW (4)
Diagram 6.2
5232
UNION (5)
CLIP (5)
DATA
LABEL
5216
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 6.5.
Fromthefluepositionmarks,checkthattheflueterminalwillbe
in a suitable position, see diagram 3.6.
6.3 Flue Hole Cutting
Cut the hole horizontally in the wall, to the diameter shown in
diagram 6.4, using, preferably, a core drill.
Diagram 6.5
6.4 Wall Sleeve
Note: If required, an optional Wall Sleeve Kit, Part No. 900862,
is available, complete with fixing instructions.
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 long screws.
Secure the boiler mounting frame to the wall using
No.10x50mm long screws.

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7 Flue Preparation
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 1, 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 1, 2 or 3metre flue system.
Allflue systemsareinstalled inasimilarmanner tothestandard
flue.
7.2 Rear Flue
Mark the air duct assembly and the flue duct at the lengths
shownindiagram7.1and7.2, then cut to length, cutting square
and removing any burrs.
7.3 Side Flue
Mark the air duct assembly and the flue duct at the lengths
shown in diagram 7.1 and 7.3 then cut to length, cutting square
and removing any burrs.
7.4 Air Duct
Locate the flue duct and air duct in the flue elbow, making sure
thattheflueductislocatedintheflueterminalandtheflueelbow
but is free to move to allow for expansion.
Checkthattheflueterminalisinthecorrectpositionandsticking
outthecorrect distance from the outsidewall face, see diagram
7.1 and appropriate diagram 7.2 or 7.3.
Drillahole,diameterasshownindiagram7.4,ineachsideofthe
airduct,through the holes in theflue elbow. Secure the air duct
totheflueelbowusingthetwoscrewssuppliedinthelooseitems
pack.
Seal around the joint between the air duct and the flue elbow
using the tape provided in the loose items pack.
Stick the self-adhesive seal, supplied in the flue pack, around
the air duct, in a position so that it will be flush with the outside
wall when installed, see diagram 7.5.
Iftheboiler is not to be fittedforsome time, cover the hole inthe
wall
7.5 Internal Access Flue
If access to the outside wall surface is not practical, the flue
system can be installed from inside. Use of the optional wall
sleeve kit is recommended, see diagram 7.5.
Diagram 7.1
Diagram 7.2
X + 125 ( FLUE DUCT )
X
BOILER
MOUNTING
WALL
OUTSIDE
WALL
FACE
( AIR DUCT ASSEMBLY)X + 173
Diagram 7.3
Y
Y + 229
(AIR DUCT
ASSEMBLY)
OUTSIDE
WALL FACE
2301
(FLUE DUCT)
SIDE OF
BOILER
MOUNTING
FRAME
Y + 181
SIDE FLUE DUCTS
STANDARD OR LONG
FLUE TERMINAL
REAR DUCT STANDARD - LONG
2335
2333
FLUE
TERMINAL
FLUE
DUCT
OUTSIDE
WALL
FACE
22
63
2334
2302
Diagram 7.5
INTERNAL ACCESS
FLUE
TERMINAL
SEAL
WALL
SLEEVE
Diagram 7.4
FLUE AIR DUCT
FLUE
ELBOW
SCREW (2)
AIR DUCT
FLUE DUCT
FLUE
TERMINAL TAPE
3.3 DIA HOLE IN EACH
SIDE OF THE AIR DUCT
AIR
DUCT
OUTSIDE
WALL FACE

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Diagram 8.1
8 Gas and Water Connections
Diagram 8.2
2298
'NOTCH' MARKING POSITION OF
SAFETY VALVE DISCHARGE BOILER
MOUNTING
FRAME
2297
DOMESTIC
COLD
WATER
SUPPLY IN
CENTRAL
HEATING
FLOW GAS
SERVICE
COCK
CENTRAL
HEATING
RETURN
DOMESTIC
HOT
WATER
OUT
63
SLOT (CLOSED)
SLOT
(CLOSED)
DRAIN POINT
8.1 Gas Connection
Provision is made for the gas supply to be connected from
below or through the wall at the rear of the boiler, see diagram
8.1 for position.
Refer also to “Gas Supply”, Section 1.7.
Make the gas supply connection to the gas service cock.
Slacken or remove the clip, as preferred, while making the
connection. Donotsubject the gas service cockto heat as you
may damage the seals.
8.2 Water Connections
Provision is made for the domestic cold water inlet to be
connected from below or through an internal wall at the rear of
the boiler, see diagram 8.1 for position. Refer also to Section
5 “Domestic Hot Water System”.
Provision is made for the domestic hot outlet, heating flow and
return to be connected from below, through an internal wall at
therear of the boilerorfromabove,passing down either sideof
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.
If necessary, temporarily fit the boiler, refer to Section 10.1,
“Mounting the Boiler”.
Flush out the domestic water and heating system before
connecting the boiler.
Make the connections to the domestic hot water outlet and the
heating system by means of the isolating valves, see diagram
8.1.
Slacken or remove the clips, as preferred, while making the
connections. Do not subject any of the isolating valves to heat
as you may damage the seals.
Make sure that the drain points on the isolating valves are
positionedtowardsthefrontoftheboiler,alsothatthedrainand
operating screw heads are accessible.
8.3 Safety Valve Discharge
WARNING. Itmustnotdischargeaboveanentranceorwindow
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
downwards, preferably over a drain. The pipe must have a
continuousfallandberoutedtoapositionsothatanydischarge
ofwater,possiblyboiling,orsteamcannotcreateanydangerto
persons,damagetopropertyorexternalelectricalcomponents
and wiring.
Note. Toeasefutureservicingitisadvisabletouseacompression
type fitting to extend the discharge pipe.

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9 Electrical Connections
Diagram 9.1
2643
1
2
3
N
L
E
RED LINK
Remove when
connecting any
heating system
controls. CABLE
CLAMP
MAINS
CABLE
COVER
SCREW (2)
9.1 Supply Cable Connection
CAUTION: To prevent an induced current from switching the
central heating on, when not required, it is important that the
heating system control cables are separated from the other
mains supply cables.
The boiler requires a permanent mains supply through an
external isolator which must also isolate any heating system
controls, see diagram 9.2.
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 9.1.
Using PVC cable of a suitable length and rating as stated in
Section1.8“ElectricalSupply”,connectthemainssupplycable
to the appropriate terminals of the connector, see diagram 9.2.
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 9.1.
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 to make sure that the polarity is
correct.
9.2 Heating System Controls
CAUTION: To prevent an induced current from switching the
central heating on, when not required, it is important that the
heating system control cables are separated from the other
mains supply cables.
The heating system should have installed: a programmer and
room thermostat controlling the boiler.
Thermostatic radiator valves may be installed in addition to the
room thermostat.
Note: For further information, see The Building Regulations
1991-Conservationoffuelandpower,1995edition-Appendix
G, table 4b.
If electrical controls are not to be used to regulate the heating
system, do not disturb the red link cable.
Whenanyformofelectricalcontrolisbeingusedtoregulatethe
heatingsystem, remove the red linkcable and connect heating
system controls in series.
The mains cable outer insulation must not be cut back external
to the plug.
9.3 Clock/Timer Kit
Aninternalclock/timerkitcanbesupplied,refer totheliterature
supplied with it.
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)withthecover,usingthetwoscrewspreviouslyremoved,
see diagram 9.1.
Clip the connector into position with the cable(s) at the back.
Secureallcablesintheclampimmediatelybehindtheconnector.
Ifnecessaryalsosecurecablestothewall,usingsuitablecable
clips.
Keep all cables away from hot surfaces.

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9 Electrical Connections
Diagram 9.2
JUNCTION
BOX
3 AMP
FUSE
LN
230V~50Hz
PERMANENT MAINS
SUPPLY
230V~50Hz
ROOM STAT. 230V~50Hz FROST STAT.
TO BOILER
RED LINK.
REMOVE WHEN
CONNECTING
SYSTEM CONTROLS
5 POLE CONNECTOR ON
MOUNTING FRAME
230V~50Hz
POTENTIAL
FROST STAT.
230V~50Hz
POTENTIAL
ROOM STAT.
(3) (L) (N) (2) (1)
JUNCTION
BOX
3 AMP
FUSE
LN
230V~50Hz
PERMANENT MAINS
SUPPLY
230V~50Hz
ROOM STAT. USED AS LINK
230V~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
230V~50Hz
PERMANENT MAINS
SUPPLY
230V~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
230V~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
230V~50Hz
PERMANENT MAINS
SUPPLY
230V~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
230V~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
INTEGRAL CLOCK
INTEGRAL CLOCK
INTEGRAL CLOCK
INTEGRAL CLOCK
INTEGRAL CLOCK
5217
EXTERNAL CLOCK

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10 Boiler Fixing
FASCIA
SECURING
SCREW (3)
CONTROL HOUSING
SECURING SCREW (2)
SECURING
SCREW
(To support the
control housing if
necessary)
CONTROL HOUSING
COVER SECURING
SCREW
CONTROL
HOUSING
COVER
3894 S
Diagram 10.1
2795
UNION
CONNECTION
Diagram 10.2
'NOTCH'
DISCHARGE PIPE
10.1 Mounting the Boiler
Afterinstallingtheboilermountingframe,domesticandheating
watersystems,makingtheelectricalconnectionsandpreparing
the flue components, carry on as below:
Lift the boiler into position, hooking it on the boiler mounting
frame at the top, then loosely fit the two boiler securing screws
at the top, see diagram 6.3.
10.2 Gas and Water Connections
Locate the boiler water pipes into the isolation valves and the
gasservicecockunionhalves. Fullypushtheboilerbacktothe
mounting frame, locating the studs into the clips.
Make the compression joint on the isolating valves and join the
gasservicecockunion. Secureallofthevalvesandgasservice
cock with the clips.
10.3 Boiler Securing
Secure the boiler by tightening the two boiler securing screws
at the top.
10.4 Discharge Pipe
Removethetwocontrol housingsecuringscrews, seediagram
10.1.
Removethecontrolhousingandsupportthecontrolhousingon
a surface or by screwing it to the front edge of the base, using
one of the securing screws, see diagram 10.1.
If required , to improve access, the air pressure switch can be
removed, refer to the service instructions, section 4.31.
Fittheshortdischargepipetothesafetyvalveusingthenutand
olive supplied loose, see diagram 10.2.
Extendthedischargepipe,usingonlyacompressiontypefitting
tojointhedischargeextension,referalsotoSection8.3“Safety
Valve Discharge”.
10.5 Clock/timer Kit (if applicable)
Fit the clock/timer kit following the appropriate sections of the
instructions supplied with it.
10.6 Electrical Connector
Connect the two halves of the electrical connector together.
Clip the connector into position on the boiler mounting frame.
Secure the cables with cable clamp immediately behind the
connector.
Carry out preliminary electrical system checks as below:
1. Test insulation resistance to earth of mains cables.
2. Test earth continuity and short circuit of all cables
3. Test the polarity of the mains.
FASCIA