Glowworm Ultimate 70FF Release note

Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
One Contact Total Service
Customer Services:
Tel: [phone]
Fax: [phone]

Installation & Servicing Instructions
220683B.11.96
Tobeleftwiththeuser
70FF 80FF
GC41 319 86 GC41 319 60
4098
Fanned Flue Boiler
Reference in these instructions to British Standards Regulations/Requirements apply only to the United Kingdom.
For Ireland the rules in force must be used.
This is a Cat I2H Appliance
BS 6332
BS 5258

2
220683B


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
RC
1
/ 2 (
1
/ 2 in. BSPT)
MODEL A B C D E F G H J K L M N P
80FF 70 300 63 146 78 360 146 94 700 574 14 63 130 38
Diagram 1.1
1 G e n e r a l
The instructions consist of two parts, Installation and
Servicing Instructions and Instructions for Use, which
includes the Guarantee Registration Card.
The instructions are an integral part of the appliance and
must, to comply with the current issue of the Gas Safety
(Installation and Use) Regulations, be handed to the user
on completion of the installation.
Important Notice
This boiler is for use only on G20 gas.
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 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.
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
The installation of the boiler must be carried out by a
competent person in accordance with the relevant
requirements of the current issue of:
The manufacturer’s instructions, supplied.
The Gas Safety (Installation and Use) Regulations, The
Building Regulations, Local Water Company Byelaws,
The Health and Safety at Work Act, Control of
Substances Hazardous to Health (COSHH), The
Electricity at Work Regulations and any local
regulations which may apply.
Detailed recommendations are contained in the current
issue of the following British Standards and Codes of
Practice.
BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1,
BS5449, BS6891, BS6700, BS7074 Part 1 and 2,
BS7593, BS7671.
Manufacturer’s instructions must not be taken as
overriding statutory requirements.
All dimensions are given in millimetres (except as noted)

3220683B
1.2 Data
See Table 1 and diagram 1.1.
All dimensions are given in millimetres (except as
noted).
1.3 Range Rating
This boiler is range rated and may be adjusted to suit
individual system requirements.
Table 2 gives the ratings and settings.
1 G e n e r a l
DATA TABLE 1.
MODEL
TOTAL DRY
WEIGHT
(Including
Terminal)
LIFT
WEIGHT
WATER
CONTENT
GAS
CONNECTION
ELECTRICITY
RATING
WATER
CONNECTION
ELECTRICITY
SUPPLY
DATA LABEL
70FF/80FF
51 kg (112 lb)
45.3 kg (100lb)
3.35 litre (0.74 gallon)
Rc 1/2in.
71W
Internal fuse F1A
2x22mm copper pipes from
top of case
240V~50Hz, fused 3A
Bottom right hand side of case
TABLE 2. 80FF
RANGE RATING
NOMINAL kW
HEAT
INPUT Btu/h
NOMINAL kW
HEAT
OUTPUT Btu/h
BURNER m bar
SETTING
PRESSURE in. w.g.
APPROX. m3/h
GAS
RATE ft3/h
Min. Medium Max.
25.97 27.65 29.31
88,600 94,300 100,000
20.52 21.98 23.45
70,000 75,000 80,000
12.8 14.5 16.3
5.1 5.8 6.5
2.4 2.6 2.7
86 92 97
BURNER INJECTOR MARKING: 205710
BURNER INJECTOR SIZE: 4.0 mm
PILOT INJECTOR MARKING: 7218
TABLE 2. 70FF
RANGE RATING
NOMINAL kW
HEAT
INPUT Btu/h
NOMINAL kW
HEAT
OUTPUT Btu/h
BURNER m bar
SETTING
PRESSURE in. w.g.
APPROX. m3/h
GAS
RATE ft3/h
Min. Medium Max.
22.39 24.03 25.64
76,400 82,000 87,500
17.58 19.05 20.52
60,000 65,000 70,000
13.3 15.3 17.2
5.3 6.1 6.9
2.0 2.2 2.4
74 80 85
BURNER INJECTOR MARKING: 205701
BURNER INJECTOR SIZE: 3.8 mm
PILOT INJECTOR MARKING: 7218

4
220683B
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
Hepworth Heating Ltd.
Any alteration that is not approved by Hepworth Heating
Ltd., could invalidate the B.S.I. Certification of the
boiler, warranty and could infringe the current issue of
the Statutory Requirements.
CE Mark
1. Directive 90/396/EEC on the approximation of the
Laws of the Member States relating to appliances
burning gaseous fuels.
2. Directive 73/23/EEC on the harmonization of the
Laws of the Member States relating to electrical
equipment designed for use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the
Laws of the Member States relating to electromagnetic
compatibility.
1.5 Gas Supply
The gas installation shall be in accordance with the
current issue of BS6891.
The supply from the governed meter must be of adequate
size to provide a steady inlet working pressure of
20mbar (8in wg) at the boiler.
On completion test the gas installation for soundness
using the pressure drop method and suitable leak
detection fluid, purge in accordance with the above
standard.
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.
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 General
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.
1.9 Drain
System
A draining 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 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 may be installed in any room, although
particular attention is drawn to the requirements of the
current issue of BS7671 with respect to the installation
of a boiler in a room containing a bath or shower.
The electrical provisions of the Building Standards
(Scotland) apply to such installations in Scotland.
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.

5220683B
1.12 Boiler Clearances
Refer to diagram 1.2.
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 1.2.
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 3.
1.15 Timber Frame Building
If the boiler is to be installed a timber frame building it
should be fitted in accordance with the British Gas
publication “Guide for Gas Installation in Timber
Framed Housing”, reference DM2. If in doubt seek
advice from the local gas undertaking or Hepworth
Heating Ltd.
1 General
Diagram 1.2
MINIMUM CLEARANCES FROM WALLS
CEILING, FLOOR, CUPBOARD, WORKTOPS,
AND INFLAMMABLE MATERIALS
500mm
Additional clearances may be
required for installation
65mm
6mm6mm
FRONT
VIEW
100mm
0081M
SIDE OR
REAR FLUE
5mm
5mm
TABLE 3. 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

6
220683B
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 obstructions, other terminals and
ventilation openings are shown in diagram 2.1.
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
Diagram 2.1
2 F l u e a n d V e n t i l a t i o n
MINIMUM SITING DIMENSIONS
FOR FANNED FLUE
TERMINALS POSITION
A DIRECTLY BELOW AN OPENABLE
WINDOW, AIR VENT, OR ANY OTHER
VENTILATION OPENING 300
B BELOW GUTTER, DRAIN/SOIL PIPE 75
C BELOW EAVES 200
D BELOW A BALCONY OR CAR PORT 200
E FROM VERTICAL DRAIN PIPES AND
SOIL PIPES 75
F FROM INTERNAL OR EXTERNAL
CORNERS 300
G ABOVE ADJACENT GROUND OR
BALCONY LEVEL 300
H FROM A SURFACE FACING THE
TERMINAL 600
I FACING TERMINALS 1200
J FROM OPENING (DOOR/WINDOW) IN
CAR PORT INTO DWELLING 1200
K VERTICAL FROM A TERMINAL 1500
L HORIZONTALLY FROM A TERMINAL 300
MINIMUM
SPACING
in mm
0103M
A
A
F G EA
G
G
G
B,C B,C
F F
K
K
K
C
G
L L
Under Car Port etc.
H,I
J D
F
K
0161M

7220683B
The installation of the boiler must comply with the
requirements of the current issue of BS6798.
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 MUST be fitted to a fully pumped and sealed
water systems.
Where the water system allows the boiler and pump to
operate on bypass only, the bypass connection must be at
least 2.5metres 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 flow and return.
3 W a t e r S y s t e m s
1000
750
500
250
00 5 10 15 20 25 30
Flow rate (litres/minute)
Water pressure loss
(mm head of water)
PRESSURE LOSS
OF BOILER 80FF
0088(a)M
30.6
litre/min
Design Flow Rate
The intersection point indicates the Flow Rate
required to achieve 110C temperature difference.
Diagram 3.1
PRESSURE LOSS OF BOILER
30.6
LITRE/MIN

8
220683B
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. 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 W a t e r S y s t e m s
Diagram 3.2
0089M

FEED AND
EXPANSION
CISTERN
22mm VENT
(MIN.)
15mm (MINIMUM)
COLD FEED
OPEN VENTED FULLY PUMPED WATER SYSTEM
RECOMMENDED RELATIONSHIP BETWEEN
PUMP COLD FEED AND VENT
450mm
MIN.
HEIGHT
1150mm
MIN.
RETURN FLOW
CYLINDER
PUMP
HEATING
150mm
MAX.
There must always
be a cold water path
to the return
connection
of the boiler.
BOILER 22mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE
FLOW
RET.

9220683B
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
Hepworth Heating Ltd., 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 W a t e r S y s t e m s
Diagram 3.3
FLOW
RETURN
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
BYPASS (DIAGRAMMATIC)
0091(b)M
BYPASS 22mm
MIN WITH
LOCKSHIELD
VALVE
4114
22 x 28
UNION
CONNECTION
28mm
PIPE

10
220683B
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
22mm (min)
BY-PASS WITH
LOCKSHIELD 
VALVE

RETURN
Diagram 3.4
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.
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 the
vessel size is given in the current issue of BS7074 Part 1.
Example. For an initial system design pressure of 0.7bar
the minimum total vessel volume required is 0.063xTotal
System volume.
Note. A higher initial design pressure requires a larger
volume expansion vessel.
Guidance on vessel sizing is also given in the current
issue of BS5449 and BS7074 Part 1.
The charge pressure must not be less than the static head
of the system, that is, the height of the highest point of
the system above the expansion vessel.
The water content of the boiler is given in Data Table 1.
3 W a t e r S y s t e m s
5814

11 220683B
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.
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.
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 3.5
3 W a t e r S y s t e m s

12
220683B
Diagram 4.1
Diagram 4.2
Diagram 4.3
Standard Flue terminal illustrated.
Standard Flue terminal illustrated.
4 F l u e a n d A p p l i a n c e P r e p a r a t i o n
REAR FLUE LENGTHS
Distance R = Wall thickness
STD. 75mm to 685mm
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 693mm
1M 81mm to 1023mm
2M 81mm to 2023mm
3M 81mm to 3003mm
4791
4125
4126
CARTON TOP
WALL
TEMPLATE LOOSE
ITEMS
PACK
MOUNTING
BRACKET INSTRUCTIONS
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.
The use of this collar will mean that the flue lengths will
need to be altered, full instructions are given in the kit.

13 220683B
4.3 Flue Preparation
All flue assemblies are designed for initial installation,
given that there is sufficient clearance opposite to the
flue for the installation of the flue.
If there is insufficient clearance the flue can be installed
externally from outside.
For a wall thickness up to 300mm provided there is
sufficient space available, the flue can be fully installed
from the inside.
For a wall thickness of over 300mm the external flue
hole will need to be made good from the outside.
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 Sleeve
If the wall thickness “Q” is less than 300mm cut the wall
sleeve to the required length, see diagram 4.5.
Fit the wall sleeve.
Make good around the wall sleeve at both internal and
external wall faces, through the wall sleeve if internal
access only is available.
If the wall thickness “Q” is greater than 300mm the wall
sleeve must be fitted flush with the INSIDE wall face.
If the inner end of the sleeve sticks out into the cavity
then, if desired, the wall sleeve can be trimmed back to
the depth of the inner skin of brickwork. Make good at
the internal wall face but leave the external wall face
until the flue has been fitted.
Diagram 4.4
SIDE FLUE
REAR FLUE
75mm
115mm
MINIMUM
HOLE
0098M

BOILER
CENTRE LINE FLUE
CENTRE LINE
14mm
300mm
MAX LENGTH
Q
Q
Diagram 4.5
4443
4 F l u e a n d A p p l i a n c e P r e p a r a t i o n
WALL
SLEEVE

14
220683B
Reposition the template, making sure of dimensional
alignment with the flue hole.
Mark the boiler fixing points and mounting bracket
position, see diagram 4.6.
Drill holes and plug, to suit No.12x2in woodscrews, fit
the screws allowing sufficient clearance, about 5mm, to
accept the swing brackets, see diagram 4.6.
Secure the mounting bracket to the wall with No.12x2in
woodscrews and plugs, see diagram 4.6.
4.7 Flue Duct
Mark the duct to the length required, this length allows
for expansion, see diagram 4.7 for rear flue and diagram
4.8 for side flue, then cut square and remove any burrs.
4.8 Air Duct/Terminal
Mark the duct length, see diagram 4.9 for rear flue and
diagram 4.10 for side flue, then cut square and remove
any burrs.
4 F l u e a n d A p p l i a n c e P r e p a r a t i o n
Diagram 4.6
5mm
7 dia.
BOILER
CENTRELINE
7 dia.
NO.
12x2in.
3/16in. dia.
PLUG
TOP BOILER
MOUNTING
HOLES
TEMPLATE
BOILER
MOUNTING
BRACKET
FLUE
CENTRELINE
MOUNTING
BRACKET FIXING
POINTS
BOILER
CENTRELINE
FLUE
CENTRELINE
4096
NO.
12x2in.
3/16in. dia.
PLUG

15 220683B
Diagram 4.7
Diagram 4.8
Diagram 4.9
Diagram 4.10
STANDARD FLUE
TERMINAL
Q
BOILER
CENTRE
LINE
BOILER
CENTRE
LINE
Q
T MINUS 188mm
Q PLUS 5mm
LONG FLUE
TERMINAL
LONG FLUE
TERMINAL
STANDARD
FLUE
TERMINAL
FLUE
DUCT
4128
4130
4127 4129
4 F l u e a n d A p p l i a n c e P r e p a r a t i o n

16
220683B
4.9 Air Duct/Terminal and Flue Duct
Assembly
Locate the flue duct into the air duct/terminal, see
diagram 4.11.
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 4.11, 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.
4.10 Wall thickness up to 300mm
Fit the self adhesive foam seal provided in the loose
items pack around the air duct/terminal at the position
shown in diagram 4.12.
4.11 Wall thickness over 300mm
Fit the self adhesive foam seal around the air duct/
terminal such that, when installed, the seal will be within
the wall sleeve, see diagram 4.12.
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 wall sleeve and hole such that it is
within the wall sleeve and does not stick out into the
room. see diagram 4.13. Do not push the flue assembly
too far into the holes as it has to be pulled back into the
boiler and secured.
Note that the foam seal is a tight fit in the wall sleeve, so
either the wall sleeve will need to be rigidly fixed in the
wall, that is, the cement has fully set or it can be held
from the other side whilst inserting the flue assembly.
4 F l u e a n d A p p l i a n c e P r e p a r a t i o n

17 220683B
4131
4 F l u e a n d A p p l i a n c e P r e p a r a t i o n
Diagram 4.12
10mm
Q
WALL THICKNESS-
UP TO 300mm
Q-25mm
Q
WALL THICKNESS-
OVER 300mm
FOAM
SEAL
FOAM
SEAL
4132
Diagram 4.11 Diagram 4.13
GASKET
(PRE-ATTACHED)
WALL
SLEEVE
4082
FLUE DUCT
5mm
3mm
DRILL SIZE
FLUE
MANIFOLD
SEALANT
AIR DUCT/TERMINAL
ASSEMBLY

18
220683B
WASHER
FRONT
COVER
NUT
CONTROLS
COVER
FRONT
COVER
WING
NUT
4115
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.
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.
5 B o i l e r I n s t a l l a t i o n
Diagram 5.1
4617
GASKETNUT (3)
BLANKING
PLATE
Diagram 5.2
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.

19 220683B
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.
5.6 Control Box Removal
Remove the electrical control box securing screws, see
diagram 5.8. Slide the box forward and release, hook it
onto the lip bracket at the front, see diagram 5.8.
5 B o i l e r I n s t a l l a t i o n
0167(A)M
Diagram 5.3
5mm
Pipe
omitted
for clarity
MOUNTING
BRACKET
SECURING
SCREWS (2)
SWING
BRACKET
LOCATION
PLUG
GASKET
RED
CLEAR
REAR SECURING SCREW (2)
(SLACKEN)
KEYHOLE
5874
4134
ELECTRICAL CONNECTIONS
Diagram 5.4
Diagram 5.5
AIR
PRESSURE
TUBES
SECURING
SCREWS (2)

20
220683B
Diagram 5.6
REAR
RIGHT
LEFT
Cutting 'MARK' lengths.
Lefthand flue does not require cutting.
SEALANT
FAN
DUCT
EXTENSION
REAR
3mm
dia.
drill
Diagram 5.7
FLUE ELBOW
JUBILEE
CLIP
SCREW
(2)
SEALANT
FAN DUCT
EXTENSION
FLUE
MANIFOLD
SPIGOT
VERTICAL
4089
4093
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/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.
SIDE
LEFT
SIDE
RIGHT
5 B o i l e r I n s t a l l a t i o n
FAN
DUCT
EXTENSION
(REAR FLUE OUTLET ILLUSTRATED)