Saunier Duval Xeon 100ff Operating manual

11865
Fanned Flue Boiler
120ff
GC No. 41-920-36
To be left with the user
Instructions for Use
Installation and Servicing
2000225135A.03.03
Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT

2
2000225135A
Thank you for installing a new Saunier Duval appliance in your home.
Saunier Duval appliances' are manufactured to the very highest standard so we are pleased
to offer our customers' a Comprehensive First Year Guarantee.
In the center pages are to be found your Guarantee Registration Card, which we recommend you complete
and return as soon as possible.
If your guarantee registration return literature is missing you can obtain a copy by telephoning
Heatcall our Customer Service Company 00 44(0)1773 828100.
RECORD YOUR SAUNIER DUVAL APPLIANCE DIRECT BY CALLING
0044 (0)208 247 9857
Customer service :
Saunier Duval GB Great Britain :
Tel. [phone]
Fax. [phone]
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
Saunier Duval IE IRELAND:
Tel. 00 353 (0)14191919
Fax. 00 353 (0)14584806
Hevac ,
Muirfield Drive
Naas Road
Dublin 12
Technical Advice Line:
Tel. [phone]
General and Sales enquiries:
Tel. [phone]
Fax. [phone]
Guarantee Registration

32000225135A
Contents
Important Information 4
Draining 5
Appliance Introduction 5
Appliance Safety Devices 6
Maintenance and Servicing 6
Instructions for Use 7
General Data 1 9
Flue Terminal 2 12
Water Systems 3 13
Flue and Appliance Preparation 4 16
Boiler Installation 5 20
Flue Fixing 6 22
Electrical Connectors 7 23
Commissioning 8 24
Instructions to the User 9 28
Servicing 10 28
Fault Finding 11 31
Replacement of Parts 12 35
Spare Parts 13 38
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
SERVICING
INSTRUCTIONS

4
2000225135A
Important Information
Gas safety (Installation and use) Regulations
In your interests and that of gas safety, it is the law that ALL gas
appliances are installed and serviced by a competent person in
accordance with the above regulations.
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. The
requirements are: The installation of this boiler must be
carried out by a competent person in accordance with the
current rules in force in the countries of destination at the
time of installation. Manufacture's instructions supplied.
Manufacture's instructions must not be taken as overriding
statutory requirements.
Mandatory WARNING for EEC countries
This appliance is designed, approved and inspected to meet
the requirements of the Intended market. The data label
indicates where the product was manufactured and the
country for which it is intended.
CE Mark
This boiler meets the requirements of Statutory Instrument
No. 3083 The boiler (Efficiency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on
the efficiency requirements for new hot water boilers fired
with liquid or gaseous fuels.
Type test for purposes of Regulation 5 certified by: Notified
body 0086.
Product/production certified by: 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.
Control of Substances Hazardous to Health
The adhesives and sealants used in this appliance are cured
and give no known hazard in this state.
Insulation pads / ceramic fibre
These can cause irritation to skin, eyes and the respiratory
tract.
If you have a history of skin complaint you may be suscepti-
ble to irritation. High dust levels are usual only if the material
is broken.
Normal handling should not cause discomfort, but follow
normal good hygiene and wash your hands before eating,
drinking or going to the lavatory.
If you do suffer irritation to the eyes or severe irritation to the
skin seek medical attention.
The insulation is composed of non-combustible material.
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 Device
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.
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.
All external wiring between the appliance and the electrical
supply and earthing requirements shall comply with the current
IEE 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 PVC 85oC insulated cable, not less
than 0.75mm2(24/0.20mm).
Gas leak or fault
WARNING: If a gas leak or fault exists or is suspected, turn the
boiler off and consult the local gas supply company or your
installation/service company.
Manual Handling Guidance
During the appliance installation it will be necessary to employ
caution and assistance whilst lifting as the appliance exceeds
the recommended weight for a one man lift.
In certain situations it may be required to use a mechanical
handling aid.
Take care to avoid trip hazards, slippery or wet surfaces.

52000225135A
Heating System Controls
The heating system must be controlled as described in the
relevant part of the current issue of :
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.
3) The domestic heating and hot water guide to the building
regulations 2001.
Thermostatic radiator valves may be installed, however they
must not be fitted in a room where the room thermostat is
located.
Air in the heating system
Persistent air in the heating system may indicate leaks in the
system or corrosion taking place. Call your Installation/Servicing
company.
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.
Draining
Important Information
Draining
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 to 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.
Appliance Introduction
The Xeon 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.
The boiler is for use only on G20 gas.
The boiler can be used on an open vented or sealed water
system.
When used on an open vented system domestic hot water can
only be provided by pumped circulation to the indirect cylinder.

6
2000225135A
Maintenance and Servicing
Appliance Safety Devices
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.
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 Cut-off
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.
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.
Maintenance and Servicing
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.
To obtain service, please call your installer or Heatcall (Saunier
Duval’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.
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 Hepworth Heating Ltd.
If a part is required contact Heatcall (Saunier Duval’s own
service organisation) using the telephone number on the inside
front cover of this booklet.
Please quote the name of the appliance, this infomation will be
on the front cover of this booklet and also on the data label inside
the appliance.
If in doubt seek advice from the local gas company or Heatcall
(Saunier Duval’s own service organisation) using the telephone
number on the inside front cover of this booklet.
Boiler casing
CAUTION. Do not remove or adjust the casing in any way, as
incorrect fitting may result in faulty operation. If in doubt, consult
your installation/service company.

72000225135A
Please read these instructions and follow them carefully for the
safe and economical use of your boiler.
Important Notice
This boiler is for use only on natural gas (G20).
Warning: The user shall not interfere with or adjust sealed
parts.
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.
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 wiring must be in accordance with the current issue of
BS7671.
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
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.
Instructions for Use
4140
Diagram 1
10264
CONTROLS COVER
DATA &
SERIAL
NUMBER
LABEL
RESET
BUTTON
VIEWING WINDOW
SETTING POINT
CONTROL
THERMOSTAT
KNOB GAS SERVICE
COCK (Shown
Off)

8
2000225135A
11854
6mm
6mm
65mm
6mm
6mm
6mm
160mm
500mm
Additional clearances may be
required for installation
FRONT
VIEW
Diagram 2
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.
Instructions for Use

92000225135A
SIDE ELEVATION FRONT ELEVATION
B
AO
C
P
L
C
L
M
F
G
H
PUMPED FLOW PUMPED RETURN
K
JWATER CONNECTIONS
28mm COPPER PIPE
GAS CONNECTIONS
RC
1
/ 2 (
1
/ 2 in. BSPT)
MODEL ABCDEFGHJ KLMO
120ff 67 300 63 127 114 450 168 132.5 835 772 63 132 43
P
78.5
D
E
Diagram 1.1
Important Notice
This boiler is for use only on G20 gas.
This boiler can be used on an open vented or sealed water
system.
When used on an open vented system domestic hot water can
only be provided by pumped circulation to the indirect cylinder.
Wherever possible, all materials, appliances and components
used shall comply with the requirements of applicable British
Standards.
Where no British Standard exists, 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 appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
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.
Note: For further information, see the current issue of the
Building Regulations, approved document L1 ( in the UK) 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.
An optional programmer for fitting on the boiler is availble, kit no.
458065.
1.2 Data
See Table 1
All dimensions are given in millimetres (except as noted).
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is
Xeon 120ff = 78.1.
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 General Data
11860

10
2000225135A
1.3 Range Rating
This boiler is range rated and may be adjusted to suit individual
system requirements.
Diagram 1.2 gives the ratings and settings.
*Note: Lift weight is with Flue Elbow, Controls Cover and Front
Cover removed.
1.4 B.S.I. Certification
This boiler is certificated to the current issue of BS6332 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 also 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 for soundness using the
pressure drop method and suitable leak detection fluid, purge
in accordance with the above standard.
1.6 Contents of Packaging
The boiler is delivered in one pack, refer to Section 4.1 for
contents.
Refer to Section 4.2 to check that the flue terminal assembly
supplied is suitable.
1 General Data
DATA TABLE 1.
TOTAL DRY
WEIGHT
(Including
Terminal)
LIFT WEIGHT
WATER
CONTENT
GAS
CONNECTION
ELECTRICITY
RATING
WATER
CONNECTION
ELECTRICITY
SUPPLY
DATA LABEL
Rc 1/2in.
97W
Internal fuse F1 & F2 (F1A)
2x28mm copper pipes from
top of case
230V~50Hz, fused 3A
Bottom right hand side of case
71.0 kg
(157 lb)
63.3 kg
(140 lb)
3.8 litres
(0.84 gal)
11855
*
Diagram 1.2
11856
1.7 Water System
This boiler may be fitted to an open vented or sealed water
system.
1.8 Safety Valve
A safety valve need not be fitted to an open vented system.

11 2000225135A
1.9 Location
This boiler is not suitable for outdoor installation.
This boiler may be installed in any room, although particular
attention is drawn to the installation of a boiler in a room
containing a bath or shower where reference must be made to
the relevant requirements.
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.
Any electrical switch or boiler control utilising mains electricity
should be placed so that it cannot be touched by a person using
the 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.
1.10 Boiler Clearances
Refer to diagram 1.3.
The 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.
Sufficient clearance must be left in front of the boiler for
servicing.
1.11 Room Ventilation
The boiler is room sealed and does not require the room or
space containing it to have permanent airvents.
1.12 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 are given in Table 3.
1.13 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 Hepworth Heating Ltd.
1.14 Heating System Controls
The heating system should have installed: a programmer and
room thermostat controlling the boiler.
11854
6mm
6mm
65mm
6mm
6mm
6mm
160mm
500mm
Additional clearances may be
required for installation
FRONT
VIEW
MINIMUM CLEARANCES FROM WALLS
CEILING, FLOOR, CUPBOARD, WORKTOPS,
AND INFLAMMABLE MATERIALS
PLAN
VIEW
TABLE 3. COMPARTMENT AIR VENTS
VENTILATION
REQUIREMENTS
VENTILATION
FROM
ROOM
OR SPACE
VENTILATION
FROM
OUTSIDE
HIGH LEVEL
VENT AREA
LOW LEVEL
VENT AREA
396 61.5 396 61.5
cm2in2cm2in2
198 30.5 198 30.5
Diagram 1.3
1 General Data
11862
Note: For further information, see the current issue of the
Building Regulations, approved document L1 (in the UK) 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. BRESCU.

12
2000225135A
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. 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
Under Car Port etc.
H,I
JD
F
K
Diagram 2.1
0103M
4307
A
A
F
GE
A
G
G
G
B,C B,C
FF
K
K
K
C
G
LL
2 Flue Terminal
MINIMUM SITING DIMENSIONS FOR
FANNED FLUE TERMINALS POSITION
A DIRECTLY BELOW, ABOVE OR HORIZONTALLY
TO AN OPENING, AIR BRICK, OPENING WINDOWS,
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 25
F FROM INTERNAL/EXTERNAL CORNERS
OR TO A BOUNDARY ALONGSIDE
THE TERMINAL 25
G ABOVE ADJACENT GROUND OR BALCONY LEVEL 25
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
M FROM INTERNAL CORNERS 25
MINIMUM
SPACING in mm
M

13 2000225135A
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 (20o), between the flow and
return, with the control 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
system.
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 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 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".
3.6 Indirect Cylinder
For all systems supplying domestic hot water the cylinder must
be indirect. It is recommended that the indirect cylinder be fitted
with some form of temperature control.
3.7 Fully Pumped Heating and Domestic Hot
Water
The connections for this type of system MUST be as shown in
diagram 3.2 and 3.3.
It is recommended that plastic pipes for primary pipework
should not be used with this boiler.
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 the 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 BS4814, BS5449, BS6759, BS6798 and
BS7074 Part 1 and 2, see diagram 3.4 for a 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 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 BS7074 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.
3 Water Systems
Flow rate (litres/minute)
Water pressure loss
(mm head of water)
PRESSURE LOSS
OF BOILER
Design Flow Rate
11863
750
500
250
0
0 5 10 15 20 25 30 35 40 45
700mm (120FF )
Diagram 3.1

14
2000225135A
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, for IE refer to the current edition of
I.S.813 "Domestic Gas Installations".
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 of 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 if the indirect coil type.
It must be suitable for working at a gauge pressure of 0.35bar
above the safety valve setting.
Diagram 3.2
6349
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 28mm (MINIMUM)
BY-PASS WITH
LOCKSHIELD VALVE
FLOW
RET.
Diagram 3.3
28mm
PIPE
FLOW RETURN
4273
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)
BYPASS 28mm
MIN WITH
LOCKSHIELD
VALVE
1metre Min.
27 metres
Max.
INDIRECT
CYLINDER
ALTERNATIVE
SYSTEM
CONTROL
VALVES
HEATING
SYSTEM
PUMP
FULLY PUMPED CIRCULATION
BYPASS (DIAGRAMMATIC)
BYPASS 28mm
MIN WITH
LOCKSHIELD
VALVE
22mm VENT & 15mm COLD FEED
TO BE FITTED IN ACCORDANCE
WITH BS 5449
6459
6466
3 Water Systems

15 2000225135A
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 the
Local Water Company Byelaws, 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.
3.17 Water Makeup
NOTE: All open vented systems must electrically bridge
out the low water pressure switch, see diagram 7.2.
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
6252
(Make-up
alternatives)
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 Water Systems

16
2000225135A
4.1 Flue Position and Length
Determine flue applications, length and terminal position before
starting.
Refer to diagram 4.1 or 4.2.
Note. If a longer flue duct is required DO NOT extend the
ducting.
A 1 or 2 metre flue system and terminal MUST be used, for this
appliance.
Note: If required, an optional Wall Liner Kit, part No.452481, is
available, complete with fixing instructions.
4.2 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.
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.
Diagram 4.2
6854
Standard Flue terminal illustrated.
SIDE FLUE LENGTHS
Distance S = External wall face to boiler case
STD. 81mm to 346mm
1M 81mm to 830mm
2M 81mm to 1830mm
Diagram 4.1
4275
Standard Flue terminal illustrated.
REAR FLUE LENGTHS
Distance R = Wall thickness
STD. 75mm to 438mm
1M 75mm to 928mm
2M 75mm to 1928mm
'R'
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 Flue and Appliance Preparation

17 2000225135A
4.3. Rear and Side Flue Application
Take the template from the boiler pack and 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 4.3.
For a side flue, extend the centre line horizontally left or right to
the corner of the adjacent surface where the flue is required to
exit. Mark the position of the centre of the flue and boiler, then
remove template as diagram 4.3.
4.4 Flue Hole Cutting
Having marked out the flue centre cut a hole for the flue using,
preferably, a 120mm minimum core drill.
4.5 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 4.4.
Note, the mounting bracket has additional holes to allow for
further fixings should site conditions require it.
Drill holes and plug, to suit No.12x2in woodscrews, fit the
screws allowing sufficient clearance, about 5mm, to accept the
swing brackets, see diagram 4.4.
Secure the mounting bracket to the wall with No.12x2in
woodscrews and plugs, see diagram 4.4.
If the boiler is not to be fitted for some time, cover the hole in the
wall.
Diagram 4.3
120 mm
MINIMUM
HOLE
127mm
SIDE FLUE
FLUE/BOILER
CENTRE LINE
4277
Diagram 4.4
7dia.
TEMPLATE
BOILER
MOUNTING
BRACKET
FLUE/BOILER
CENTRE LINE
5mm
3/16in. dia.
PLUG
NO.
12x2in.
MOUNTING
BRACKET FIXING
POINTS
FLUE/BOILER
CENTRE LINE
194
172
65.5
749
TOP BOILER
MOUNTING
HOLES
172.5
172.5
4278
4 Flue and Appliance Preparation

18
2000225135A
4.6 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 4.1.
For a side flue, measure the distance from the outside wall face
to the boiler centre line. Check that the flue length will be
suitable, see diagram 4.2.
All 2 metre flue systems are installed in a similar manner to the
standard flue.
4.7 Rear Flue
Mark the air duct/terminal assembly and the flue duct at the
length shown in diagram 4.5 and 4.7 then cut to length, cutting
square and removing any burrs.
Note, do not cut the flue duct at the pre-drilled end.
4.8 Side Flue
Mark the air duct/terminal assembly and the flue duct at the
lengths shown in diagram 4.6 and 4.8 then cut to length, cutting
square and removing any burrs.
Note, do not cut the flue duct at the pre-drilled end.
4.9 Flue Assembly
Locate the flue duct (drilled end) onto the flue elbow and secure
with the screws supplied in the loose items pack, see diagram
4.9.
Locate the flue duct/elbow into the air duct/terminal spigot and
the air duct/terminal into the flue elbow making sure the correct
alignment of top. Drill the air duct and secure/seal (external
fixing, do not seal) as shown in diagram 4.9.
4.10 Wall Liner
If a wall liner is used, fit foam seal as diagram 4.10.
Diagram 4.5
Diagram 4.6
Diagram 4.7
FLUE
DUCT
Q PLUS 72mm
Q
BOILER
CENTRE
LINE
T MINUS 55mm
Q PLUS 72mm
LONG FLUE
TERMINAL
STANDARD FLUE
TERMINAL
Q
T
6855
6856
6857
4 Flue and Appliance Preparation

19 2000225135A
Diagram 4.8
T MINUS 55mm
BOILER
CENTRE
LINE
LONG FLUE
TERMINAL
STANDARD FLUE
TERMINAL
T
6858
Diagram 4.9
NOTE:
THE FLUE TERMINAL
RESTRICTOR MUST BE
POSITIONED AS SHOWN
SECURING
SCREW (2)
FLUE ELBOW
FLUE DUCT SEALING TAPE
AIR DUCT/
TERMINAL
FLUE ELBOW
DUCT
STANDARD FLUE TERMINAL
3mm
DRILL
4284
Diagram 4.10
WALL THICKNESS-
UP TO 300mm
Q
FOAM
SEAL
WALL THICKNESS-
OVER 300mm
20mm
FOAM
SEAL
Q
Q MINUS 55mm
6859
4 Flue and Appliance Preparation

20
2000225135A
5.1 Boiler Preparation
IMPORTANT: With regards to the Manual Handling Operations,
1992 Regulations, the following lift operation exceeds the
recommended weight for a one man lift.
With the boiler still in the bottom tray, slide the controls cover
upwards and remove it as shown in diagram 5.1.
Remove the front cover by undoing (and keeping) the wing nut,
nut and shakeproof washer, then lift the front cover off, see
diagram 5.1.
Place the front cover on one side until required, having removed
the polystyrene packing piece.
Fit suitable compression fittings to the boiler connections.
5.2 Mounting the Boiler
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 5.2.
Diagram 5.1 Diagram 5.2
CONTROLS
COVER
FRONT
COVER
SHAKEPROOF
WASHER
NUT
WING
NUT 5mm
Pipe
omitted
for clarity
11857
4286
MOUNTING
BRACKET
SWING
BRACKET
SECURING
SCREWS (2)
Remove the blue and red electrical connections from the fan,
see diagram 5.3.
Break the air pressure switch tube connections from the fan,
see diagram 5.3.
Remove the fan assembly by removing the screws and sliding
out, see diagram 5.3. Take care not to damage the gasket.
Slacken, but do not remove, the flue hood securing screws, see
diagram 5.4.
5 Boiler Installation