Glowworm Ultimate 70FF Operating manual

4098
2000225233A.10.04
All replacement parts
All labour charges
All call-out charges
Guarantee Registration
Fanned Flue Boiler
Cat II2H3P
BS 6332
BS 5258
Reference in these instructions to British Standards and Statutory
Regulations/Requirements apply only to the United Kingdom.
For Ireland the rules in force must be used.
To be left with the user
❏
✔
❏
✔
❏
✔
Instructions for Use
Installation and Servicing
G.C. No. 41-047-57 G.C. No.41-047-58
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0800 073 2142
70FF 80FF
Cat I2H
Tel: [phone]
Fax: [phone]
Glow-worm,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
www.glow-worm.co.uk
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.
We recommend you complete and return your Guarantee Registration Card as soon as possible.
If this card is missing you can obtain a copy or record your registration by telephoning the Glow-worm 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.
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.

2
2000225233B
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 Glow-worm.
Any alteration not approved by Glow-worm, 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 0086.
Product/productioncertifiedby: Notified body 0086.
The CE mark on this appliance shows compliance with:
1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels.
2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to 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.
INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.
Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health.
CERAMIC FIBRE/INSULATION PADS.
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 of the eyes or severe irritation to the skin seek medical attention.
THERMOSTATS
These contain very small amounts of xylene in the sealed phial and capillary. If broken, under normal circumstances the fluid does not cause a
problem, but in case of skin contact, wash with cold water. If swallowed drink plenty of water and seek medical attention.
CUT-OFF DEVICES
These contain activated charcoal and a very small amount of chlorodifluormethane in the sealed phial and capillary. If broken, under normal
circumstances the fluid does not cause a problem. If there is irritation to the eyes or skin then seek medical attention.
SPARE PARTS
REMEMBER: When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance
specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Glow-worm.
Important Information
Introduction 3
Lighting the Boiler 4
General Data 1 5
Flue & Ventilation 2 8
Water Systems 3 9
Flue and Appliance Preparation 4 12
Boiler Installation 5 17
Commissioning 6 21
Instructions to User 7 24
Servicing 8 24
Fault Finding 9 26
Replacement Parts 10 31
Spare Parts 11 35
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
SERVICING
INSTRUCTIONS

32000225233B
4140
Diagram 1
4625
CONTROLS COVER
DATA &
SERIAL
NUMBER
LABEL
RESET
BUTTON
VIEWING WINDOW
SETTING POINT
CONTROL
THERMOSTAT
KNOB GAS SERVICE
COCK (Shown
Off)
To obtain service, please call your installer or Glow-worm’s own
Service Organisation using the telephone number given on the
controls tray.
Please be advised that the ‘Benchmark’ logbook should be
completed by the installation engineer on completion of
commissioning and servicing.
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boiler Logbook. You can check your installer is CORGI registered
by calling CORGI direct on :- 01256 372300.
Boiler Clearances
If fixtures are positioned close to the boiler space must be left as
shown in diagram 2. At least a minimum clearance of 500mm
must be left in front of the boiler to allow for servicing.
Boilers Installed in a Compartment or
Cupboard
If the boiler is installed in a compartment or cupboard do not
obstruct any ventilation openings.
Do not use the compartment or cupboard for storage.
Introduction
WARNING: It is important that the case (not the controls tray)
is not disturbed or removed other than for servicing by a
competent person.
The user shall not interfere with or adjust sealed parts.
Please read these instructions and follow them carefully for the
safe and economical use of your boiler.
The Ultimate FF series are fanned flue boilers designed to
provide central heating and indirect domestic hot water.
The boiler is fully automatic in operation having only one user
control, the control thermostat.
IMPORTANT NOTICE
If your boiler has been converted to use L.P.G. Propane the
following applies:
NOTE: Propane cylinders are under pressure and should never
be stored or used indoors residentially.
They should only be kept outside.
Under no circumstances should L.P.G. Propane cylinders be
fitted or stored in basement areas or boiler houses.
The Gas Safety (Installation and Use)
Regulations
In your interest and that of gas safety it is the law that ALL gas
appliances are installed by a competent person in accordance
with the above regulations.
Gas Leak or Fault
Turn off the gas emergency control valve immediately. Eliminate
all sources of ignition, i.e.smoking, blowlamps, hot air guns etc.
Do not operate electrical lights or switches either on or off. Open
all doors and windows,ventilate the area.
Electrical Supply Failure
Failure of the electrical supply will cause the burner to go out.
Should this occur, operation of the appliance will normally
resume after the electrical supply is restored.
If the boiler does not relight after an electrical supply failure the
overheat safety cutoff device may need resetting, remove the
controls cover and press the reset button, refer to diagram 1.
Overheat Safety Cutoff
If the overheat safety cutoff device operates on any other
occasion than an electrical supply failure, press the reset button
as in “Electrical Supply Failure”. If the overheat operates again,
turn the appliance off and contact your installation/servicing
company.
Maintenance
To ensure the continued efficient and safe operation of the boiler
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 in the UK there
is a duty or care imposed on the owner of the property by the
current issue of The Gas Safety (Installation and Use)
Regulations, Section 35.
It is the law that any servicing is carried out by a competent
person.
Instructions for Use

4
2000225233B
500mm
Additional clearances may be
required for installation
65mm
6mm6mm
FRONT
VIEW
100mm
0081M
SIDE OR
REAR FLUE
5mm
5mm
Diagram 2
Cleaning
WARNING: This appliance contains metal parts (components)
and care should be taken when handling and cleaning, with
particular regard to edges.
Clean the casing occasionally by wiping it over with a damp
cloth or dry polishing duster.
Do not use an abrasive cleaner.
Boiler Electrical Supply
WARNING: This boiler must be earthed.
The boiler must only be connected to a 230V~50Hz supply
protected by a 3A fuse.
All system components shall be of an approved type and shall
be connected in accordance with the current issue of BS7671
and any applicable local regulations.
External wiring must be correctly earthed, polarised and in
accordance with the relevant standards.
In GB this is BS 6891.
In IE this is the current edition of I.S.813 "Domestic Gas
Installations".
Wiring to the boiler must be PVC insulated type to the current
issue of BS6500 Table 16, not less than 0.75mm2(24/0.20mm).
The colours of three core flexible cable are:
Brown - live, Blue - neutral,
Green/yellow - earth.
As the markings on your plug may not correspond with these
colours continue as follows:
The cable coloured blue must be connected to the terminal
marked “N” or black.
The cable coloured brown must be connected to the terminal
marked “L” or red.
The cable coloured green/yellow must be connected to the
terminal marked “E”, or green or the earth symbol .
To Light the Boiler
WARNING: Sealed Systems
Do not operate the boiler wthout water.
A sealed water system must be filled and pressurised by a
competent person.
Only light the boiler when you are sure that the system has been
filled and pressurised.
The pressure gauge should show at least 0.7bar, anything less
than this figure could indicate a leak and you MUST contact your
installation/servicing company.
If there is any doubt about the boiler being full of water consult your
installation/servicing company.
ALL SYSTEMS:
Turn the electrical supply on to the boiler and check that all remote
controls are calling for heat.
To Turn the Boiler On
Remove the controls cover, by withdrawing it forward and off, see
diagram 1.
Turn the control thermostat knob clockwise to any position between
MIN and MAX. The maximum temperature setting is about 82oC
(180oF), see diagram 1.
The boiler lighting operation is now automatic as follows.
The fan operates, followed by an ignition spark until the pilot is lit.
When the pilot is alight the ignition system switches off and the
main burner lights. The flames can be seen through the viewing
window, see diagram 1.
The main burner will remain alight until switched off by the control
thermostat or any remote control.
If the boiler is switched OFF, by hand, wait at least 30 seconds
before switching on again.
When the boiler switches off, both the pilot and main burner go out.
The automatic lighting sequence will operate again when heat is
required.
Refit the controls cover.
It should be noted that this is a fan flue appliance and fan operation
may be heard.
To Turn the Boiler Off
For short periods, turn the control thermostat knob anti-clockwise
to “O” Off. To relight, turn the control thermostat knob to any
position between “MIN” and “MAX”.
For longer periods, turn the control thermostat knob fully anti-
clockwise to “O” Off and switch off the electrical supply to the
boiler.
To relight follow the lighting sequence given above.
Protection Against Freezing.
If the boiler is to be out of use for any long period of time during
severe weather conditions we recommend that the whole of the
system, including the boiler, be drained off to avoid the risk of
freezing up. Make sure that, if fitted, the immersion heater in the
cylinder is switched off.
For the position of the serial number, see diagram 1.
Instructions for Use

52000225233B
;
;
SIDE ELEVATION FRONT ELEVATION
B
AP C
D
EJL
M
C
L
D
N
F
G
H
PUMPED RETURN PUMPED FLOW
K
0075(a)M
;
;
;
;
;
;
WATER CONNECTIONS
22mm COPPER PIPE
GAS CONNECTIONS
RC1/2(1/2in. BSPT)
MODEL A B C D E F G H J K L M N P
70FF/80FF 70 300 63 146 78 360 146 94 700 574 14 63 130 38
1 General Data
Diagram 1.1
IMPORTANT NOTICE
This boiler is for use on Natural Gas (G20) as distributed in the
United Kingdom and Ireland but may be converted for use on
G31 gas (Propane L.P.G.) with an available conversion kit. Kit
No. 2000462101. This boiler must be installed by a competent
person ONLY.
This boiler can be used on open vented or sealed water
systems.
When used on an open vented system domestic hot water can
only be provided by a pumped primary circulation.
Wherever possible, all material, appliances and components
used shall comply with requirements of applicable British
Standards.
Where no British Standards exist, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
Refer to Manual Handling Operations, 1992 regulations.
Sheet Metal Parts
WARNING: When installing or servicing this boiler care should
be taken when handling sheet metal parts, to avoid any possibility
of personal injury.
1.1 Statutory Requirements
In GB the installation of the boiler must be carried out by a
competent person as described in the following regulations:
The manufacturer’s instructions supplied.
The Gas Safety (Installation and Use) Regulations.
The appropriate Buildings Regulations either The Building
Regulations, The Building Regulations (Scotland),The Building
Regulations (Northern Ireland).
The Water Fittings Regulations or Water byelaws in Scotland.
The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).
The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a competent
person and installed in accordance with the current edition of
I.S.813 "Domestic Gas Installations", the current Building
Regulations and reference should be made to the current ETCI
rules for Electrical Installation.
In GB the following Codes of Practice apply:
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1,
BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593,
BS7671.
In IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
1.2 Data
See Table 1 and diagram 1.1.
All dimensions are given in millimetres (except as noted).
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is
(70) 79.4%,(80) 79.4%.
The value is used in the UK Government’s Standard Assessment
Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated have been certified by B.S.I.
1.3 Range Rating
This boiler is range rated and may be adjusted to suit individual
system requirements.
See diagram 1.2 for ratings and settings.

6
2000225233B
1 General Data
DATA TABLE 1.
MODEL
TOTAL DRY
WEIGHT
(Including
Terminal)
LIFT
WEIGHT
WATER
CONTENT
GAS
CONNECTION
ELECTRICITY
RATING
WATER
CONNECTION
ELECTRICITY
SUPPLY
DATA LABEL
70FF
APPROX. m3/h
GAS
RATE ft3/h
80FF
APPROX. m3/h
GAS
RATE ft3/h
70FF/80FF
51 kg (112 lb)
45.3 kg (100lb)
3.35 litre (0.74 gallon)
Rc 1/2in.
71W
Internal fuse F1 & F2 (F1A)
2x22mm copper pipes from
top of case
230V~50Hz, fused 3A
Bottom right hand side of case
1.4 B.S.I. Certification
This boiler is certificated to the current issue of British Standard
6332 Part 1, invoking the current issue of BS5258 Part 1 for
performance and safety. It is, therefore, important that no
alteration is made to this boiler without permission, in writing,
from Glow-worm.
Any alteration that is not approved by Glow-worm, could
invalidate the B.S.I. Certification of the boiler, warranty and
could infringe the current issue of the Statutory Requirements.
1.5 Gas Supply
The gas installation shall be in accordance with the relevant
standards.
In GB this is BS6891.
In IE this is the current edition of I.S.813 "Domestic Gas
Installations".
The supply from the governed meter must be of adequate size
to provide a steady inlet working pressure of 20mbar (8in wg) at
the boiler.
On completion test the gas installation using the pressure drop
method and suitable leak detection fluid, purge in accordance
with the current issue of BS6891.
1.6 Electrical Supply
WARNING: This boiler must be earthed.
All system components shall be of an approved type and shall
be connected in accordance with the current issue of BS7671
and any applicable local regulations.
Diagram 1.2
9906 9907
Min. Medium Max.
2.02
71.0
2.18
77.0
2.34
83.0
2.36
83.0
2.51
89.0
2.67
94.0
External wiring must be correctly earthed, polarised and in
accordance with the relevant standards.
In GB this is BS 6891.
In IE this is the current edition of I.S.813 "Domestic Gas
Installations".
Connection of the boiler and system controls to the mains
supply must be through a common isolator and must be fused
3A, maximum. This method of connection must be by a fused
double pole isolating switch, with a minimum contact separation
of 3mm on both poles. The switch should be readily accessible
and preferably adjacent to the appliance. It should supply the
appliance only and be easily identifiable as so doing.
Alternatively, an unswitched shuttered socket outlet and 3A
fused 3 pin plug, both to the current issue of BS1363 may be
used provided that they are not used in a room containing a bath
or shower.
Wiring to the boiler must be to the current issue of BS6500 Table
16, not less than 0.75mm2(24/0.20mm).
1.7 Contents of Packaging
The boiler is delivered in one pack, refer to Section 4.1 for
contents.
1.8 Water System
This boiler may be fitted to an open vented or a sealed water
system.

72000225233B
Diagram 1.3
500mm
Additional clearances may be
required for installation
65mm
6mm6mm
FRONT
VIEW
100mm
0081M
SIDE OR
REAR FLUE
5mm
5mm
1 General Data
1.9 Drain
System
A drain tap must be provided at the lowest points of the system
which will allow the entire system, boiler and hot water cylinder
be drained.
Draining taps should be to the current issue of BS2879.
Boiler
A draining point is fitted at the bottom right hand side of the heat
exchanger.
Cover controls to avoid water damage.
If required remove the combustion chamber front cover to
improve access.
1.10 Safety Valve
A safety valve need not be fitted to an open vented system.
1.11 Location
This boiler is not suitable for outdoor installation.
This boiler is suitable for installation in bathroom zones 2 and 3.
The boiler may be installed in any room, although particular
attention is drawn to the requirements of BS7671 with respect
to the installation of a boiler in a room containing a bath or
shower. Any electrical switch should be so positioned that it
cannot be touched by a person using the bath or shower. The
electrical provisions of the Building Standards (Scotland)
Regulations apply to such installations in Scotland.
In GB this is the current I.E.E. WIRING REGULATIONS and
BUILDING REGULATIONS.
In IE reference should be made to the current edition of I.S.813
"Domestic Gas Installations" and the current ETCI rules.
The boiler must be mounted on a flat wall which is sufficiently
robust to take its total weight.
The boiler may be fitted to a wall made of combustible material.
1.12 Boiler Clearances
Refer to diagram 1.3.
This boiler must be positioned so that at least the minimum
operational and servicing clearances are provided.
Additional clearances may be required for installation.
If fixtures are positioned next to the boiler they should be made
removable for access to pipework.
At least a minimum of 500mm clearance must be left in front of
the boiler for servicing, see diagram 1.3.
1.13 Room Ventilation
The boiler is room sealed and does not require the room or
space containing it to have permanent air vents.
1.14 Boilers in a Compartment
Where the installation of the boiler will be in an unusual position,
special requirements are needed, the current issue of BS6798
gives detailed guidance on these requirements.
A compartment used to enclose the boiler must be designed
and constructed specifically for this purpose. An existing
cupboard or compartment modified for the purpose may be
used. Details of essential requirements for cupboard or
compartment design are given in the current issue of BS6798.
The doorway opening should be of sufficient size to allow for
easy removal of the boiler.
Where the boiler is fitted in a cupboard or compartment,
permanent high and low level ventilation must be provided. The
minimum ventilation areas required are given in Table 2.
1.15 Timber Frame Building
If the boiler is to be installed in a timber frame building it should
be fitted in accordance with the Institute of Gas Engineers
document IGE/UP/7/1998. If in doubt seek advice from the local
gas undertaking or Glow-worm.
1.16 Heating System Controls
The heating system should have installed: a programmer and
room thermostat controlling the boiler.
Thermostatic radiator valves may be installed, however they
must not be fitted in a room where the room thermostat is
located.
NOTE: For further information, see the current issue of the
Building Regulations, approved document L1, and the
references:
1) GIL 59, 2000: Central heating system specification (CheSS)
and
2) GPG 302, 2001: Controls for domestic central heating
system and hot water. BRECSU.
TABLE 2. COMPARTMENT AIR VENTS
VENTILATION HIGH LEVEL LOW LEVEL
REQUIREMENTS VENT AREA VENT AREA
VENTILATION
FROM ROOM
OR SPACE
VENTILATION
FROM
OUTSIDE
MODEL cm2in2cm2in2
80FF 264 41 264 41
70FF 231 35 231 35
80FF 264 41 264 41
70FF 231 35 231 35
80FF 132 21 132 21
70FF 116 18 116 18
80FF 132 21 132 21
70FF 116 18 116 18
MINIMUM CLEARANCES FROM WALLS, CEILING,
FLOOR, CUPBOARD, WORKTOPS, AND
INFLAMMABLE MATERIALS

8
2000225233B
2 Flue and Ventilation
A
A
F
GE
A
G
G
G
B,C B,C
FF
K
K
K
C
G
LL
Diagram 2.1
MINIMUM SITING DIMENSIONS
FOR FANNED FLUE
TERMINALS POSITION
ADIRECTLY BELOW, ABOVE OR
HORIZONTALLY TO AN OPENING,
AIR BRICK, OPENING WINDOW,
AIR VENT OR ANY OTHER
VENTILATION OPENING. 300
BBELOW GUTTER, DRAIN/SOIL PIPE 75
CBELOW EAVES 200
DBELOW A BALCONY OR CAR PORT 200
EFROM VERTICAL DRAIN PIPES AND
SOIL PIPES 75
FFROM EXTERNAL CORNERS 300
GABOVE ADJACENT GROUND OR
BALCONY LEVEL 300
HFROM A SURFACE FACING THE
TERMINAL 600
IFACING TERMINALS 1200
JFROM OPENING (DOOR/WINDOW) IN
CAR PORT INTO DWELLING 1200
KVERTICAL FROM A TERMINAL 1500
LHORIZONTALLY FROM A TERMINAL 300
MFROM INTERNAL CORNERS 25
MINIMUM
SPACING
in mm
0103M
Under Car Port etc.
H,I
JD
F
K
M
NOTE: Detailed recommendations for flue are given in the
current issue of BS5440 Part 1.
2.1 Terminal Position
The minimum acceptable siting dimensions for the terminal
from obstruction, other terminals and ventilation openings are
shown in diagram 2.1. For Ireland the minimum distances for
flue terminal positioning must be those detailed in I.S.813
"Domestic Gas Installations".
The terminal must be exposed to the external air, the position
allowing free passage of air across it at all times.
Car ports or similar extensions of a roof only, or a roof and one
wall, require special consideration with respect to any openings,
doors, vents or windows under the roof. Care is required to
protect the roof if it is made of plastic sheeting. If the car port
consists of a roof and two or more walls, seek advice from the
local gas company before installing the boiler.
If the terminal is fitted within 600mm below plastic guttering or
painted soffit 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.
2.2 Terminal Guard
A terminal guard is required if persons could come into contact
with the terminal or the terminal could be subject to damage.
If a terminal guard is required, it must be positioned to provide
a minimum of 50mm clearance from any part of the terminal and
be central over the terminal.
A suitable guard, reference Type “K3”, can be obtained from:
Tower Flue Components Ltd
Morley Road
Tonbridge
Kent
TN9 1RA

92000225233B
1000
750
500
250
0
051015 20 25 30
Flow rate (litres/minute)
Water pressure loss
(mm head of water)
5945
Design Flow Rate
30.6
L /min
26.8
L /min
80FF
70FF
Diagram 3.1
3 Water Systems
The installation of the boiler must comply with the requirements
of the current issue of BS6798, in Ireland, refer also to the current
edition of I.S.813 "Domestic Gas Installations".
In GB it is necessary to comply with the Water Supply (Water
Fittings) Regulations 1999 (for Scotland, the Water Byelaws
2000, Scotland).
To comply with the Water regulations your attention is drawn to:
The Water Regulations guide published by the Water Regulations
Advisory Service (WRAS) gives full details of the requirements.
In IE the requirements given in the current edition of I.S.813
"Domestic Gas Installations" and the current Building Regulations
must be followed.
3.1 Frost Protection
If the position of the boiler is such that it may be vulnerable to
freezing it should be protected as specified in the current issue of
BS5422. It is recommended that a frost protection thermostat be
fitted.
3.2 Pump
The pump, with integral valves, should be fitted in the heating flow
pipework from the boiler, it should be set to produce a temperature
difference of 11oC (20oF) between the flow and return, with the
boiler thermostat set at “MAX”, which is about 82oC (180oF).
The pressure loss of the boiler can be found from diagram 3.1.
High resistance microbore systems may require a higher duty
pump.
3.3 Bypass - Fully Pumped and Sealed Water
System
A bypass is usually unnecessary on systems using a 3 port
diverter valve since one port will remain in the open position at all
times. This allows satisfactory operation of the pump overrun.
However if thermostatic radiator valves are fitted to all radiators
or two port valves are used a bypass is required.
The bypass connection must be at least 2.5 metres away from the
boiler.
The flow through the boiler must not be allowed to fall such that
there is a temperature difference greater than 20oC between the
flow and return.
3.4 Water System
For an open vented system the boiler must be supplied from an
unrestricted water supply taken from a feed and expansion
cistern fitted at a maximum height of 27metres above the boiler.
The cold feed must be 15mm minimum size.
It is important that the relative positions of the pump, cold feed
and open vent are as shown in diagram 3.2.
The unrestricted open vent from the boiler must rise continuously
to discharge over the feed and expansion cistern.
3.5 Domestic Hot Water System
General - All domestic hot water circuits, connections, fittings
must be in accordance with the relevant standards and water
supply regulations.
For GB: Guidance G17 to G24 and recommendation R17 to R24
of the Water Regulations Guide.
For IE: The current edition of I.S.813 "Domestic Gas Installations".
The domestic hot water service must be in accordance with the
current issue of BS5546, refer also to the current issue of
BS6700.
3.6 Cylinder
For all systems supplying domestic hot water the cylinder must
be indirect. It is recommended that the cylinder be fitted with
some form of temperature control.
3.7 Fully Pumped Domestic Hot Water
The connection for this type of system MUST be as shown in
diagram 3.2 and 3.3.
3.8 Inhibitor
Attention is drawn to the current issue of BS5449 and BS7593
on the use of inhibitors in central heating systems.
If an inhibitor is to be used, contact a manufacturer or Glow-
worm, for their recommendations as to the best product to use.
When installing in an existing system take special care to drain
the entire system, including radiators, then thoroughly cleaning
out before installing the boiler whether or not adding an inhibitor.
3.9 Sealed Water Systems
The installation should comply with the appropriate requirements
of the current issue of BS4841, BS5449, BS6759, BS6798 and
BS7074 Part 1 and 2, see diagram 3.4 for suggested layout.
3.10 Safety Valve
A safety valve must be fitted to a sealed water system.
It shall be preset, nonadjustable with a lift pressure of 3bar,
incorporating seating of a resilient material, a test device and a
connection for drain.
The drain from the safety valve must be routed clear of any
electrical fittings and positioned so that any discharge can be
seen.
PRESSURE LOSS OF BOILER

10
2000225233B
3 Water Systems
Diagram 3.2
6458
FEED AND
EXPANSION
CISTERN
22mm VENT
(MIN.)
15mm (MINIMUM)
COLD FEED
OPEN VENTED FULLY PUMPED WATER SYSTEM
RECOMMENDED RELATIONSHIP BETWEEN
PUMP COLD FEED AND VENT
450mm
MIN.
HEIGHT
1150mm
MIN.
RETURN FLOW
CYLINDER
PUMP
HEATING
150mm
MAX.
BOILER
IF REQUIRED
22mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE
FLOW
RET.
Diagram 3.3
1metre Min.
27 metres
Max.
22mm VENT & 15mm COLD FEED
TO BE FITTED IN ACCORDANCE
WITH BS 5449
INDIRECT
CYLINDER
ALTERNATIVE
SYSTEM
CONTROL
VALVES
HEATING
SYSTEM
PUMP
FULLY PUMPED CIRCULATION
SYSTEM (DIAGRAMMATIC)
6462
IF REQUIRED
BYPASS 22mm
MIN WITH
LOCKSHIELD
VALVE
28mm
PIPE
RETURN
FLOW
4114
1metre Min.
27 metres
Max.
22mm FOR COMBINED FEED & VENT
TO BE FITTED IN ACCORDANCE
WITH BS 5449
INDIRECT
CYLINDER
ALTERNATIVE
SYSTEM
CONTROL
VALVES
HEATING
SYSTEM
PUMP
FULLY PUMPED CIRCULATION
BYPASS (DIAGRAMMATIC)
6463
IF REQUIRED
BYPASS 22mm
MIN WITH
LOCKSHIELD
VALVE
3.11 Expansion Vessel
A diaphragm type expansion vessel, conforming to the current
issue of BS4814 (see also BS7404 Part 1 and 2) must be
connected at a point close to the inlet side of the circulating
pump, see diagram 3.4 unless laid down differently by the
manufacturer.
The expansion vessel volume depends upon the total water
system volume and the initial system design pressure. For any
system an accurate calculation of vessel size is given in the
current issue of BS5449 and BS7074 Part 1, for IE refer to the
current edition of I.S.813 "Domestic Gas Installations".
Example. For an initial system design pressure of 0.7bar the
minimum total vessel volume required is 0.063xTotal System
volume.
NOTE: A higher initial design pressure requires a larger volume
expansion vessel.
The charge pressure must not be less than the static head of the
system, that is, the height of the highest point of the system
above the expansion vessel.
The water content of the boiler is given in Data Table 1.
3.12 Pressure Gauge
A pressure gauge with a set pointer and covering at least the
range 0 to 4bar (0 to 60lb/in2) shall be permanently fitted to the
system in a position where it can be seen when filling the
system.
22 X 28
UNION
CONNECTION

11 2000225233B
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
Diagram 3.4
3 LITRES (0.66 gals)
MAKE-UP BOTTLE
(if required)
NON-RETURN
VALVE
AUTO
AIR
VENT
FLOW
DRAIN
COCK
BOILER
SAFETY
VALVE
(Make-up
alternatives) EXPANSION
VESSEL
PRESSURE
GAUGE
CIRCULATING
PUMP
FILLING POINT
AIR
RELEASE
POINT
HEATING CIRCUIT
IF REQUIRED
22mm (min)
BY-PASS WITH
LOCKSHIELD
VALVE
RETURN
6465
3 Water Systems
Diagram 3.5
3.13 Domestic Hot Water Cylinder
SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE.
The domestic hot water cylinder must be of the indirect coil type.
It must be suitable for working at a gauge pressure of 0.35bar
above the safety valve setting.
3.14 Domestic Hot Water System - Unvented
Where a storage system will not have a vent to atmosphere the
installation must comply with Building Regulations and local
Water Company Bye-laws, see also the current issue of BS6700.
If fitting into an existing system the local authority must also be
advised.
3.15 Filling a Sealed Water System
Provision for filling the system at low level must be made. Three
methods are shown in diagram 3.5. There must be no permanent
connection to the mains water supply, even through a non-
return valve.
3.16 Water Makeup
Provision must be made for replacing water lost from the
system. A make up vessel mounted above the highest point of
the system and connected through a non-return valve to the
system on the return side of either the hot water cylinder or
heating system, see diagram 3.4.
Alternatively provision for make up can be made by a filling loop.

12
2000225233B
4 Flue and Appliance Preparation
Diagram 4.1
Diagram 4.2
Diagram 4.3
Standard Flue terminal illustrated.
Standard Flue terminal illustrated.
6827
6828
REAR FLUE LENGTHS
Distance R = Wall thickness
STD. 75mm to 505mm
1M 75mm to 1015mm
2M 75mm to 2015mm
3M 75mm to 2995mm
SIDE FLUE LENGTHS
Distance S = External wall face to boiler case
STD. 81mm to 513mm
1M 81mm to 1023mm
2M 81mm to 2023mm
3M 81mm to 3003mm
4791
CARTON
TOP
LOOSE
ITEMS PACK
WALL
TEMPLATE
INSTRUCTIONS
MOUNTING
BRACKET
BOILER
4.1 Unpacking
Open the carton, check the items supplied against the boiler
pack contents list on the flap, see diagram 4.1.
4.2 Flue Position and Length
Determine flue application, length and terminal position before
starting.
Refer to diagram 4.2 or 4.3.
If you are using a Flue Bend or a Vertical Flue Kit, please follow
the instructions supplied with that kit.
To make a neat finish to the flue outlet a flue collar kit, part No.
443286, with instructions, is available.
NOTE: The use of this collar will mean that the flue lengths will
need to be altered, full instructions are given in the kit.
NOTE: If required, an optional Wall Sleeve Kit, part No.900862,
is available, complete with fixing instructions.
4.3 Flue Preparation
All flue assemblies are designed for internal installation (optional
wall liner is required), given that there is sufficient clearances
opposite to the flue for the installation of the flue.
If there is insufficient clearance the flue can be installed from
outside.

13 2000225233B
4 Flue and Appliance Preparation
Diagram 4.4
SIDE FLUE
REAR FLUE
75mm
115mm
MINIMUM
HOLE
0098M
BOILER
CENTRE LINE
FLUE
CENTRE LINE
14mm
For a wall thickness up to 300mm, provided that there is
sufficient space and the optional wall liner kit is used the flue can
be fully installed from the inside.
For a wall thickness of over 300mm the external flue hole will
need to be made good from the outside. This applies also if you
use the flue kit without the optional kit, irrespective of wall
thickness.
4.4 Rear and Side Flue Application
Select the boiler location and flue application, with due regard
to the terminal position.
Take the template from the boiler pack and temporarily position
it on the wall, making sure that the minimum clearances are
maintained, see diagram 1.2.
For a rear flue mark the position of the flue as diagram 4.4.
For a side flue, extend the centre line horizontally left or right to
the corner adjacent surface where the flue is required to exit to
outside. Mark the position of the centre of the flue and boiler,
see diagram 4.4.
4.5 Flue Hole Cutting
Having marked out the flue centre cut a hole for the flue using,
preferably, a 115mm minimum core drill.
4.6 Wall Mounting Bracket
Reposition the template, making sure of dimensional alignment
with the flue hole.
Mark the boiler fixing points and mounting bracket position, see
diagram 4.5.
Diagram 4.5
5mm
TEMPLATE
FLUE
CENTRELINE
BOILER
MOUNTING
BRACKET
BOILER
CENTRELINE
MOUNTING
BRACKET FIXING
POINTS
FLUE
CENTRELINE
BOILER
CENTRELINE
TOP BOILER
MOUNTING
HOLES
7 dia.
7 dia.
3/16 in dia.
PLUG
NO.
12x2in
3/16 in dia.
PLUG
NO.
12x2in
4096

14
2000225233B
Diagram 4.6
Diagram 4.7
Diagram 4.8
FLUE
DUCT
LONG FLUE
TERMINAL
STANDARD FLUE
TERMINAL
Q PLUS 5mm
Q
BOILER
CENTRE
LINE
T MINUS 188mm
6833
6831
6829
4 Flue and Appliance Preparation
Drill holes and plug, to suit No.12x2in woodscrews, fit the
screws allowing sufficient clearance, about 5mm, to accept the
swing brackets, see diagram 4.5.
Secure the mounting bracket to the wall with No.12x2in
woodscrews and plugs, see diagram 4.5.
4.7 Flue Duct
Mark the duct to the length required, this length allows for
expansion, see diagram 4.6 for rear flue and diagram 4.7 for
side flue, then cut square and remove any burrs.
4.8 Air Duct/Terminal
Mark the duct length, see diagram 4.8 for rear flue and diagram
4.9 for side flue, then cut square and remove any burrs.
4.9 Air Duct/Terminal and Flue Duct Assembly
Locate the flue duct into the air duct/terminal, see diagram 4.10.
Take the flue manifold from the loose items pack together with
the sealant. Place the sealant onto the flue manifold.
Fully locate the flue manifold in to the air duct/terminal and flue
duct assembly as shown in diagram 4.10, make sure the correct
alignment of the “Top”s.
Drill two 3mm diameter holes through the air duct/terminal to the
flue manifold secure with the two self tapping screws supplied
in the loose items pack.
It should now not be possible to remove the manifold.
Q

15 2000225233B
4 Flue and Appliance Preparation
Diagram 4.9
BOILER
CENTRE
LINE
LONG FLUE
TERMINAL
STANDARD
FLUE
TERMINAL
6830
4.10 Rear Fitting
Fit the self adhesive foam seal provided in the flue pack around
the air duct/terminal at the position shown in diagram 4.13.
4.11 Side Fitting
Fit the self adhesive foam seal around the air duct/terminal such
that, when installed, the seal will be within the wall, see diagram
4.14.
If dimension "A" is greater than 75mm from the wall, the self
adhesive foam seal can be dispensed with, and the area around
the flue made good in the normal way, see diagram 4.14.
Important: If the wall liner kit is used the self adhesive foam seal
included in the wall liner kit must be used in place of the one
supplied with the flue pack, see diagram 4.11 for position of self
adhesive seal.
Diagram 4.10
AIR DUCT/TERMINAL
AND FLUE DUCT
ASSEMBLY
4616

16
2000225233B
4 Flue and Appliance Preparation
4.12 Flue Assembly - Installation
If the boiler is not to be fitted for some time cover the hole in the
wall.
On limited access installations push the flue assembly into and
through the hole such that it is within the wall and does not stick
out into the room, see diagram 4.12. Do not push the flue
assembly too far into the holes as it has to be pulled back into
the boiler and secured.
4.13 Internal Access Flue
If access to the outside wall is not practical, the flue system can
be installed from inside. Use of the optional wall liner kit is
required.
Diagram 4.11
Diagram 4.12
FOAM
SEAL
FOAM
SEAL
WALL THICKNESS-
OVER 300mm
10mm
WALL THICKNESS-
UP TO 300mm
Q-25mm
Q
Q
GASKET
(PRE-ATTACHED)
6832
4082
;
;
;
;
;
;
Diagram 4.13
6930
Diagram 4.14
6931
FOAM
SEAL
"A"
REAR FITTING
SIDE FITTING
FOAM
SEAL
WITH WALL LINER KIT ONLY

17 2000225233B
5 Boiler Installation
Diagram 5.1
CONTROLS
COVER
NUT(3)
FRONT
COVER
SHAKEPROOF
WASHER
4115
NUT
5.1 Boiler Preparation
With the boiler still in the bottom tray, slide the controls tray
upwards and remove it as shown in diagram 5.1.
Remove the front cover by undoing (and keeping) the screw and
wing nuts and lifting the front cover off, see diagram 5.1.
Remove the packing piece from inside the front cover.
Place front cover on one side until required.
Fit suitable compression fittings to the boiler connections.
5.2 Mounting the Boiler
As necessary, fit the blanking plate, see diagram 5.2.
Now make sure that the top, swing brackets are UPRIGHT.
IMPORTANT: With regards to the Manual Handling Operations,
1992 Regulations, the following operation, exceeds the
recommended weight for one man lift.
Lift the boiler into position, hooking over the mounting bracket.
Swing the brackets over the two screws at the top. Hold the
swing bracket(s) in place whilst tightening the screw(s) on to it,
see diagram 5.3.
Remove the blue and red electrical connections from the fan,
see diagram 5.4.
Break the air pressure switch tube connections, see diagram
5.4.
Remove the fan assembly by removing the screws at the front,
slackening the screws at the rear and sliding it out, see diagram
5.4. Taking care not to damage the gasket.
Secure the flue assembly to the boiler using the previously fitted
dogpoint screws noting that these are keyhole fixings, see
diagram 5.5.
Make sure of the correct fitting of the flue to the boiler.
For a side outlet cut the fan duct extension to the length
required, see diagram 5.6.
Remove any burrs and fit as diagram 5.6.
Fit the fan duct extension to the elbow and assembly to the fan,
see diagram 5.6
Do not secure at this point with the screw.
Position the fan assembly and engage the fan duct extension
over the flue manifold. Make sure, by pushing in the flue duct
extension that a secure seal is made. Mark the final position of
the fan duct extension in the screw hole on the elbow, remove
the assembly, seal with sealant, supplied in the loose items
pack and secure with the screw as diagram 5.6.
Secure the elbow to the fan outlet with the Jubilee clip.
For rear outlet cut and fit the fan duct extension as shown in
diagram 5.6.
Fit fan assembly by engaging the fan duct extension over the
flue manifold spigot, see diagram 5.7.
Secure the fan assembly with the screws previously slackened
and removed.
Reconnect the blue and red electrical connections to the fan,
the polarity of the connections is not important.
Reconnect the air pressure switch tubes as shown in diagram
5.4.
Diagram 5.2
4617
WING
NUT
GASKET BLANKING
PLATE

18
2000225233B
5 Boiler Installation
Diagram 5.4
ELECTRICAL
CONNECTIONS
REAR SECURING SCREW (2)
(SLACKEN but do not remove)
GASKET
4086
AIR PRESSURE TUBES
CLEAR RED
SECURING
SCREW (2)
0167(a)M
Diagram 5.3
5mm
MOUNTING
BRACKET
SWING
BRACKET
SECURING
SCREWS (2)
NOTE:
PIPES REMOVED
FOR CLARITY
5.3 Water Circulation System
Complete the water connections to the boiler.
Fill, vent and flush the system.
Check for any water leaks and put right.
5.4 Safety Valve Discharge
Fit a suitable discharge pipe to the safety valve and route it to
outside the building so that any discharge can be seen but will
not cause injury to persons, damage to property or any electrical
installation.
5.5 Gas Connection
Make the gas connection to the Rc1/2in gas service cock, see
diagram 6.1.
Check for leaks using a suitable leak detection fluid.
The whole of the gas installation, including the meter, should be
inspected, tested for soundness and purged in accordance with
the current issue of BS6891 and in IE the current edition of I.S.
813 "Domestic Gas Installations".
5.6 Control Box Removal
Remove the electrical control box securing screws, see diagram
5.8. Slide the box forwards and release, hook it onto the lip
bracket at the front, see diagram 5.8.
Diagram 5.5
KEYHOLE
LOCATION
LUG
4134

19 2000225233B
Diagram 5.6
Diagram 5.7
5 Boiler Installation
FLUE
MANIFOLD
SPIGOT
(REAR FLUE OUTLET ILLUSTRATED)
VERTICAL
REAR
RIGHT
LEFT
SCREW
(2)
JUBILEE
CLIP
Cutting 'MARK' lengths.
Lefthand flue does not require cutting.
SIDE
LEFT
FAN
DUCT
EXTENSION
SIDE
RIGHT
REAR
FLUE ELBOW
FAN
DUCT
EXTENSION
FAN DUCT
EXTENSION
2.5mm
dia.drill
4089
4093

20
2000225233B
Diagram 5.10
4619
3310
5 Boiler Installation
5.7 Electrical Connection
WARNING: This boiler must be earthed.
Take care not to damage any internal wiring and capillaries.
Take plastic cable retaining clip, from the loose items pack, peel
off the backing paper and position it in a suitable place to secure
the incoming cable.
Using heat resistant (to 85oC) cable of at least 0.75mm2(24/
0.2mm) to the current issue of BS6500 Table 16 and of suitable
length, thread through cable clamps, secure into the plastic
clips and connect to appropriate terminals, see diagram 5.9 and
9.5.
Standard colours are, brown - live (L), blue - neutral (N) and
green and yellow - earth (E).
The mains cable outer insulation must not be cut back external
to the cable clamp.
Make sure the cable is suitably secured.
When making connections, make sure that the earth conductor
is made of a greater length than the current carrying conductors,
so that if the cable is strained the earth conductor would be the
last to become disconnected.
5.8 Pump Connection
The pump must be connected directly to the control box, as
shown in diagram 5.9 threading the cable through the cable
clamp in the side of the control box.
5.9 External Controls
Any external controls must only be wired to interrupt the red link
between terminals SL and 9.
Make sure that the supply cable and all external cables are
secured and away from hot surfaces.
5.10 Testing
Checks to ensure electrical safety must be carried out by a
competent person.
After installation of the system, preliminary electrical system
checks as below should be carried out.
1. Test insulation resistance to earth.
2. Test continuity and short circuit of all cables,
3. Test the polarity of the mains.
The installer is requested to advise and give guidance to the
user on the controls scheme used with the boiler.
Remove red link between 9 & SL when fitting
a time control etc (if no switch is fitted, link will
make the circulation pump run constantly).
FIXING SCREWS
LIP BRACKET
IGNITION
LEAD
PUMP
CABLE
CABLE
CLAMPS
MAINS
CABLE
4620
Diagram 5.8