Glowworm swift flow 75e User manual

221138C.07.98
This is a Cat I2H Appliance
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]
Installation Instructions
Tobeleftwiththeuser
Fanned Flue Combination Boiler
5226
G.C. No. 47 313 16
G.C. No. 47 313 17
75e
80e

2
221138C
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
ALL DIMENSIONS in MILLIMETRES
KEY:
15mm COMPRESSION
DOMESTIC WATER Rc
1/2
(
1/2
in. BSPT)
GAS CONNECTION
22mm COMPRESSION
CENTRAL HEATING
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
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
80e 19.76
67,400
29.3
100,000
10.72
36,576
17.6
60,000
23.4
80,000
8.8
30000
15.8
6.3
8.5
3.6 2.2 1.0
2.1
75.8 2.8 98.6 1.2
42.1
783
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
1 G e n e r a l

3221138C
❋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
Lift Weight 37.0kg (81.4lb)
Total Weight 50.4kg (111lb)
●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)
1 G e n e r a l
■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
1 General
The instructions consist of three parts, Installation,
Servicing and Instructions for Use, which includes the
Guarantee Registration Card. The instructions are an
integral part of the appliance and must, to comply with
the current issue of the Gas Safety (Installation and Use)
Regulations, be handed to the user on completion
of installation.
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 Regulatioon 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.
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. When installing or servicing this boiler
care should be taken when handling the edges of sheet
metal parts to avoid any possibility of personal injury.
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

4
221138C
1 G e n e r a l
2267
55
5
DIMENSIONS
IN MILLIMETRES
5
Diagram 2.1
5
800
INCREASE TO 25MM CLEARANCE
FROM COMBUSTIBLE MATERIAL
150
150
2 B o i l e r P o s i t i o n
1.7 Gas Supply
The gas installation shall be in accordance with the rules
in force in the countries of destination.
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.
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 heating system controls to the electrical supply,
must be through one common isolator.
Isolation should be by a double pole switched fused spur
box, having a minimum contact separation of 3mm in
each pole. 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 be used, provided they are not used in a
room containing a bath 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) .
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 operational and servicing clearances are
provided, see diagram 2.1. Additional clearances may
be required around the boiler for installation.

5221138C
3 F l u e a n d V e n t i l a t i o n
Diagram 3.1
Diagram 3.2
DISTANCE 'Y': 80 TO 523mm
2309
WALL THICKNESS 'X': 75 TO 580mm
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'
1m DISTANCE 'X': 75 TO 898mm
2m DISTANCE 'X': 75 TO 1898mm
3m DISTANCE 'X': 75 TO 2890mm
1m DISTANCE 'Y': 80 TO 833mm
2m DISTANCE 'Y': 80 TO 1833mm
3m DISTANCE 'Y': 80 TO 2833mm
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 the elbow which can be positioned in one of three
possible directions:
Rearward, left or right.
The standard flue is able to provide the duct length 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 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.
3.3 Terminal Position
The minimum acceptable siting dimensions for the
terminal from obstructions, other terminals and
ventilation openings are shown in diagram 3.6.
The terminal must be exposed to the external air, the
position allowing free passage of air across it at
all times.
Car port or similar extensions of a roof only, or 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.

6
221138C
194
MIN.
❋
HORIZONTAL FORWARDS or BACKWARDS
ELBOW / 2 x 90o BENDS
HORIZONTAL and DOWNWARDS
ELBOW / 2 x 45o BENDS
ELBOW / 2 x 45o BENDS
ELBOW / 2 x 45o BENDS
ELBOW / 2 x 90o BENDS
234 MIN.
'Y'
'Z'
57
MIN. 168
MIN.
'X' 'Y'
194
MIN.
'X' 'Y'
'X'
3526
'X'
341 MIN.
57
MIN.
'Z'
'Y'
FLUE BEND KIT
FLUE KIT 1m Part No.448490
Part No.448468
ELBOW/TERMINAL PACK
Part No.438130 2 off
1 off
1 off
MAX. FLUE LENGTH X+Y+Z = 600mm❋
MAX. FLUE LENGTH X+Y+Z = 1800mm❋FLUE BEND KIT
FLUE KIT 2m
ELBOW/TERMINAL PACK
Part No.438130 1 off
1 off
MAX. FLUE LENGTH X+Y = 1800mm❋
FLUE BEND KIT
FLUE KIT 1m Part No.448490
Part No.448468
ELBOW/TERMINAL PACK
Part No.438130 2 off
1 off
1 off
MAX. FLUE LENGTH X+Y+Z = 600mm❋
Diagram 3.5
▲
▲
230
MIN.
194
MIN.
▲
▲
Part No.448468 1 off
Part No.448491
FLUE KIT 1m 1 off
Part No.448490
FLUE BEND KIT
FLUE KIT 2m
ELBOW/TERMINAL PACK
Part No.438130 1 off
1 off
Part No.448468 1 off
Part No.448491
FLUE KIT 1m 1 off
Part No.448490
MAX. FLUE LENGTH X+Y+Z = 1800mm❋
FLUE BEND KIT
FLUE KIT 2m
ELBOW/TERMINAL PACK
Part No.438130 1 off
1 off
Part No.448468 1 off
Part No.448491
FLUE KIT 1m 1 off
Part No.448490
▲
▲
▲
▲▲
KEY
= The maximum ‘Flue
Length’ does not include the
elbows.
= Installation clearance
IMPORTANT
For every 45 ° bend used the straight flue
length of 2metres must be decreased by
600mm minimum, this must be taken into
account when measuring the total flue length.
'X'
'Z'
'Y'
290 MIN.
▲
▲'Z'
'X'
'Y'
398 MIN.
194
MIN.
▲
▲
F l u e B e n d K i t

7221138C
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 3.6
Low Vent 248cm238in2124cm219in2
High Vent 248cm238in2124cm219in2
TABLE 2 75e
Position Air from Air Direct
of Room or from
Air Vent Internal space Outside
Low Vent 264cm240in2132cm220in2
High Vent 264cm240in2132cm220in2
TABLE 2 80e
Position Air from Air Direct
of Room or from
Air Vent Internal space Outside
3 F l u e a n d V e n t i l a t i o n
3.4 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.
3.5 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 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 3.6
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 force in the countries of destination. The boiler
is room sealed, so where the boiler is fitted in a room or
space, a permanent air 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.

8
221138C
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

9221138C
4 H e a t i n g S y s t e m
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 boiler is shown in diagram 4.1, Grundfos or diagram
4.1A, 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 should be connected into the system
as close as possible to the central heating return
connection of the boiler, see diagram 4.2.
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 unauthorised interference is not
possible. The design differential can be between 11°C
(20°F) and 17°C (30°F), dependent upon 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.
To use diagram 4.1 start with the required heating
system load.
In the example shown the 80e maximum boiler output
has been 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 example 1.9m (6ft4in) is available.
A greater 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 (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.
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.
In the example shown the 80e maximum boiler output
has been 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 example 1.9m (6ft3in) is available.
A greater 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.

10
221138C
4 H e a t i n g S y s t e m
2818
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)
Diagram 4.2
4.7 Bypass
It is essential that a bypass is fitted in all installations,
22mm o.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 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

11 221138C
4 H e a t i n g S y s t e m
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
5 D o m e s t i c H o t W a t e r S y s t e m
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: It is important that fittings used for connection to
potable 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, then thoroughly cleaning out before fitting the
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.
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 Data.
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 cold water 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.

12
221138C
6 I n s t a l l a t i o n P r e p a r a t i o n
Diagram 6.3
INNER
CASE
COVER
SECURING
SCREW (4)
Diagram 6.2
OUTER CASE
SECURING SCREW (2)
Diagram 6.1
6625
5232
UNION (5)
CLIP (5)
DATA
LABEL
5216
CENTRAL HEATING
SELECTOR SWITCH
DOOR
RESET
SWITCH + NEON
OUTER CASE
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.
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.

13 221138C
6 I n s t a l l a t i o n P r e p a r a t i o n
Diagram 6.4
Diagram 6.5
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
6.2 Marking
The boiler mounting frame is the same width as the
boiler but the 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 forwards 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 6.4 which also shows dimensions.
For rear flue, mark the rear flue position as required,
centre and/or diameter.
For a side flue, mark the horizontal flue centre line at the
sides of the template. Extend the flue centre line
horizontally left or right to the internal corner where the
flue is required to exit to outside. Mark the position of
the circular hole, on the flue exit wall, using the
dimensions given in diagram 6.5.
From the flue position marks, check that the flue
terminal will be 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.
After cutting the hole, check that it will accept the
wall sleeve.
6.4 Wall Sleeve
Note: The wall sleeve should be used for all installations.
Place the wall sleeve into the hole, flush with the outside
wall face and seal around the sleeve to make it
weatherproof on the outside and internally “good”.
Access to the outside is possible through the sleeve.
If the sleeve is too long, cut it to the same length as the
wall thickness.
For wall thicknesses over 300mm, the wall sleeve must
be fitted flush with the outside wall face. Make good the
external wall face, leave the internal wall face till later.
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.

14
221138C
7 F l u e P r e p a r a t i o n
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
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.
All flue systems are installed in a similar manner to the
standard flue.
7.2 Rear Flue
Mark the air duct assembly and the flue duct at the
lengths shown in diagram 7.1 and 7.2, 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.

15 221138C
7 F l u e P r e p a r a t i o n
23342302
Diagram 7.5
INTERNAL ACCESS
FLUE
TERMINAL
AIR
DUCT
SEAL
OUTSIDE
WALL FACE
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
7.4 Air Duct
Locate the flue duct and air duct in the flue elbow,
making sure that the flue duct is located in the flue
terminal and the flue elbow but is free to move to allow
for expansion.
Check that the flue terminal is in the correct position and
sticking out the correct distance from the outside wall
face, see diagram 7.1 and appropriate diagram 7.2 or 7.3.
Drill a hole, diameter as shown in diagram 7.4, in each
side of the air duct, through the holes in the flue elbow.
Secure the air duct to the flue elbow using the two
screws supplied in the loose items 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 loose items
pack, around the air duct, in a position so that it will be
flush with the outside wall when installed, see
diagram 7.5.
If the boiler is not to be fitted for some time, cover the
hole in the wall.

16
221138C
Diagram 8.1
8 G a s a n d W a t e r C o n n e c t i o n s
Diagram 8.2
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. Do not subject the gas service cock to
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 the rear of the boiler or from above,
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.
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 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 downwards, 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 ease future servicing it is advisable to use a
compression type fitting to extend the discharge pipe.

17 221138C
9 E l e c t r i c a l C o n n e c t i o n s
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 Section 1.8 “Electrical Supply”, connect the mains
supply cable 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 - Conservation of fuel and power,
1995 edition - Appendix G, table 4b.
If electrical controls are not to be used to regulate the
heating system, do not disturb the red link cable.
If any form of electrical control is being used to regulate
the heating system, remove the red link cable 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
An internal clock/timer kit can be supplied, refer to the
literature 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) with the cover, using the two screws
previously removed, see diagram 9.1.
Clip the connector into position with the cable(s) at
the back.
Secure all cables in the clamp immediately behind
the connector.
If necessary also secure cables to the wall, using suitable
cable clips.
Keep all cables away from hot surfaces.

18
221138C
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
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

19 221138C
1 0 B o i l e r F i x i n g
FASCIA
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
After installing the boiler mounting frame, domestic and
heating water systems, making the electrical connections
and preparing 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 gas service cock union halves. Fully push the
boiler back to the mounting frame, locating the studs into
the clips.
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.
10.3 Boiler Securing
Secure the boiler by tightening the two boiler securing
screws at the top.
10.4 Discharge Pipe
Remove the two control housing securing screws,
see diagram 10.1.
Remove the control housing and support the control
housing on 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.
Fit the short discharge pipe to the safety valve using the
nut and olive supplied loose, see diagram 10.2.
Extend the discharge pipe, using only a compression
type fitting to join the discharge extension, refer also to
Section 8.3 “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.

20
221138C
1 0 B o i l e r F i x i n g
Diagram 10.3
GASKET
2336
FLUE ELBOW
(REAR FLUE
SHOWN)
FAN
SECURING
SCREW (2)
FLUE
COLLECTOR
WING
NUT
SECURING
SCREW (4)
10.7 Flue Fixing
Fit the self-adhesive gasket, supplied in the loose items
pack, to the flue elbow, see diagram 10.3.
Push the prepared ductings into and through the wall
sleeve, the longest protrusion of the flue terminal is
positioned at the top.
Note: The foam seal is a tight fit in the wall sleeve and
the flue system should not be inserted unless the cement
has fully set or it can be held from the other side.
Fit the flue elbow to the top of the boiler, see diagram
10.6, using the four screws supplied loose. To assist
with the location of the flue elbow into the fan outlet,
loosen the two wing nuts on the flue collector angle and
the two fan securing screws.
Tighten the four screws of the flue elbow evenly to
ensure a good seal at the gasket. Tighten the wing nuts
and screws, if slackened, to secure the flue collector
and fan.
Make the wall good internally around the air duct.
Check that the ductings do not slope down towards
the boiler.