Glow-worm 23c User Manual

Instructions for Use

Installation and Servicing

To be left with the user

23c

Fanned Flue Combination Boiler

G.C. No. 47-047-18

2000225000B.02.02

10139

This is a Cat I2H Appliance

optional electro mechanical clock timer shown fitted

The instructions consist of three parts, User, Installation and Servicing Instructions, 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.

Guarantee Registration

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 Guarantee.

This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture,

whichever is the shorter, for parts. In addition this product is guaranteed for 12 months from the date of intallation or

18 months from the date of manufacture, whichever is the shorter, for labour.

The second year of the parts guarantee, from the beginning of the 13th month onwards after installation or

manufacture, is conditional upon the boiler having been serviced by a CORGI registered gas installer, in accordance

with the manufacturer's recommendations. We strongly recommend regular servicing of your gas appliance, but where

the condition is not met, any chargeable spare parts or components issued within the applicable guarantee period still

benefit from a 12 month warranty from the date of issue by the manufacturer.

We recommend you complete and return as soon as possible your guarantee registration return literature, supplied in

the document envelope.

If your guarantee registration return literature is missing you can obtain a copy or record your registration by

telephoning the Heatcall Customer Service number 01773 828100.

REGISTER YOUR GLOW-WORM APPLIANCE

CALL 0208 247 9857

One Contact Local Service

Customer Services:

Tel: [phone]

Fax: [phone]

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: [phone] Fax: [phone]

Important Information

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.

Note: The boiler serial number is marked on the label attached to the inside of the drop down door. Refer to the

'Introduction' section for a description of the basic functions of the boiler. The 'Users' section describes how to safely operate the
boiler.

Mandatory warning for CEE countries

Warning: This appliance is designed, approved and inspected to meet the requirements of the market. The identification plate

located on the inside of the appliance certifies the origin where the product was manufactured and the country for which it is
intended.
If you see any exception to this rule, please contact your nearest Glow-worm dealer.
Thank you in advance for your assistance.

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 0063.

Product/production certified by: Notified body 0063.

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

3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic
compatibility.

designed for use within certain voltage limits.

Substances Hazardous to Health

Under section 6 of the Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health.

The adhesives and sealants used in this appliance are cured and give no known hazard in this state.

INSULATION PADS/CERAMIC FIBRE, GLASSYARN, MINERAL WOOL
These can cause irritation to skin, eyes and the respiratory tract.
If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is
broken.
Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or
going to the lavatory.
If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.
The insulation is composed of non-combustible material.

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.

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.

22000225000B

Contents

CONTENTS DESCRIPTION SECTION PAGE No.

Important Information 2
Introduction 4

INSTRUCTION

FOR USE

INSTALLATION

INSTRUCTIONS

Controls and Lighting 4
Clock-timer (Optional) 6
Draining 6
Safety Devices 7
Servicing and Maintenance 7

Technical Data 1 8
Dimensions 2 9
Heating System Design 3 10
Domestic Hot Water System Design 4 10
Boiler Schematic 5 11
Boiler Location, flue and ventilation 6 12
Fixing jig pack 7 13
Piping System Installation 8 14
Boiler installation 8 15
Flue Installation telescopic and standard 10 16
Electrical Connection 11 19
Commissioning 12 20
Settings 14 22

SERVICING

INSTRUCTIONS

Routine Cleaning and Inspection 15 22
Fault Finding 16 27
Wiring Diagram 17 34
Replacement of Parts 18 35
Spare Parts 19 44

3

2000225000B

Introduction

The 23c boiler is a wall mounted modulating combination boiler
with electronic ignition providing central heating and
instantaneous hot water.

The boiler is of the I2H category for use with Natural Gas (G20)
as distributed in the United Kingdom.

The boiler has a fan assisted balanced flue which both discharges
the products of combustion to and draws the combustion air
from the outside of the room.

The boiler is suitable for top outlet flue connection only but can
be fitted with horizontal flue, vertical flue or twin-pipe flue. Refer
to flue options guide for further information, this is available from
your nearest stockist.

Both the central heating and domestic hot water temperature
are user adjustable from the boiler control panel.

Domestic hot water demand always has priority over heating
demand.

The pump, expansion vessel and associated safety devices are
all fitted within the boiler.

The boiler can be installed against either an external wall or on
an adjacent inside wall, that is, the flue system will pass directly
to the rear or to either side to the terminal fitted on the outside
wall face.

The installation must be carried out by a qualified registered
person in accordance with the relevant requirements of The
Building Regulations, The Water Byelaws, The Building
Standards (Scotland) Regulations and any applicable local
regulations.

These instructions should be carefully followed for the safe and
economical use of your boiler.

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.

o

Wiring to the boiler must be PVC 85
than 0.75mm

2

(24/0.20mm).

C insulated cable, not less

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 qualified registered
person in accordance with the above regulations.

Gas leak or fault

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.

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.

Overheating safety

In the event of a problem, the overheating safety devices cause
safety shutdown of the boiler. If this happens, call your
Installation/Servicing company.

Boiler controls

The control panel, located at the lower front of the boiler casing,
see diagram 1, allows the boiler to be started, shut down,
controlled and monitored during use.

Flue

Do not obstruct the outside terminal of the flue.

Ancillary equipment

A range of flue accessories are available including vertical
flues, twin-pipe flues, bends etc.

For further information contact your supplier.

Controls and lighting

Your 23c boiler has been factory configured to operate at the
heart of an existing installation. However, because many
installations are specially designed, do not hesitate to contact
your installer who will be able to ensure that you get the best
performance from your installation, by adjusting the heating
circuit's maximum output or temperature.

Once these settings have been made, you can still adjust the
temperature to suit your needs.

Central heating adjustment

The selector switch enables you to vary the temperature of the
water in the central heating circuit from the minimum setting
(approx. 38˚C) up to the maximum temperature set by your
installer. Most of the time, the mid position will meet your needs
but the selector should be moved nearer to the maximum
setting in very cold weather when your home is not reaching the
required temperature.

Domestic hot water

The selector switch can be adjusted from a temperature of
(approx. 35˚C up to 60˚C or more).

The ECO setting is ideally suited for all the requirements of
normal family use (showers, washing up etc.). The maximum
setting should be reserved for occasional use when very hot
water is required.

42000225000B

Controls and Lighting

1 - On/Off switch
2 - Central heating

temperature selector
3 - Domestic hot water
temperature selector
4 - Pressure gauge (bar)
and temperature gauge (ºC)
5 - Fault display
(faults indicated by a
red flashing light)

6 - Clock-timer (Optional)

1. Lighting the boiler :

4

Make sure that:

• The boiler is connected to the electrical supply.

• The gas service cock is open.

Turn the switch ON ( I )

2

3

5

9084

1

6

Diagram 1

4. Heating temperature adjustment :

• Winter: Set the control knob between 1 and 5

• Summer: Set the control knob to

2. Stop the boiler :

• Turn the switch OFF ( 0 ) the electrical supply is
OFF.

• Turn the gas supply OFF at the gas service cock if
the boiler is to be out of use for a long time.

3. Domestic hot water adjustment :

• Position ( 0 ): Domestic hot water OFF

• Position ( I ) and ECO: Domestic hot water
between approx. 35˚C and 50˚C

• ECO: Maximum recommended for constant use

• Between ECO and maxi: Occasional use for water
above approx. 50˚C

5. If a fault occurs (indicated by red flashing
light) :

• Reset boiler: Turn the On/Off switch to ( 0 ),
wait for five seconds. Turn the On/Off switch to ( I )
the boiler is reset. If the fault continues call your
Installation/Servicing company or Heatcall.
(Glow-worm’s own service organisation) using the
telephone number on the front cover
of this literature.

6. Installation filling :

• If the boiler loses water: the pressure gauge (a)

and fault display (b) will flash. Fill the system by
the filling device (c) at the bottom of the boiler until
the pressure gauge reads 1.5 bar.

(a) (b)

(c)

➜

Diagram 2

• Warning:
pressure of 2.5 bar or above indicating over
pressure, the fault display (b) will flash. The
pressure must be reduced to 1.5 bar by bleeding a
radiator. If the fault continues call your Installation/
Servicing company or Heatcall. (Glow-worm’s own
service organisation) using the telephone number
on the front cover of this literature.

5

Take care not to overfill the boiler

. At a

2000225000B

Clock-timer instructions for use

Optional Clock-timers inclusive of installation
and user instructions:- These are available
from your nearest stockist.

Electro/Mechanical Part No. 4000122022

Digital Part No. 4000120494

Draining

Protection against freezing

The boiler has a built in frost protection programme as long as
the electricity and gas are left switched on.

If the temperature within the appliance falls to 3˚C the burner
and system pump are activated.

When the temperature inside the appliance reaches 10˚C the
burner will shut down and after a short period the pump will stop.

This device primarily protects the boiler. Any other exposed
areas of the system should be protected by a seperate frost
thermostat.

If the boiler is to be out of use for any long periods during severe
weather conditions, it is recommended that the whole system,
including the boiler, be drained to avoid the risk of freezing.

If in doubt, consult your servicing company.

Draining and filling

Caution: The boiler is installed as part of a sealed system which
must only be drained and filled by a competent person.

18

62000225000B

Safety Devices

The 23c incorporates a visual fault display that indicates certain
fault conditions, (red flashing light) should they occur.

Should the boiler fail to operate during Commissioning, the
most likely fault is that the gas supply to the boiler has not been
turned on or purged sufficiently or that there is no pressure in the
heating system.

General safety devices

Air flow rate safety device

If an obstruction, even partial, of the flue occurs, for any reason
whatsoever, the built in safety system of the boiler will turn the
boiler OFF, the red light will flash and the fan will continue to run.
The boiler will be ready to operate when the fault has been
cleared.

Heating safety valve

CAUTION: A heating safety valve with a discharge pipe is fitted

to this boiler.

The valve MUST NOT BE TOUCHED except by a qualified
registered person. If the valve discharges at any time, switch the
boiler off and isolate it from the electrical supply. Contact your
installation/service company.

If the gas supply is interrupted

The boiler switches over to safety mode, the red light will flash.
Call a qualified service engineer or Heatcall (Glow-worm’s own
service organisation) using the telephone on the front cover of
this literature.

Air in pipes

Important: A central heating system can not operate correctly

unless it is filled with water and air bled from the system. If these
conditions are not met the system may be noisy.

Bleed the air in the radiators and adjust the pressure if system
requires. If the system requires filling to often this may be due
to minor leaks or corrosion in the system. Call a qualified
service engineer or Heatcall (Glow-worm’s own service
organisation) using the telephone number on the front cover of
this literature.

Frost protection

The

23c

boiler from freezing. If the boiler is to be left and there is a risk
of frost, ensure that the gas and electrical supplies are left
connected. The frost protection device will light the boiler when
the temperature of the boiler water falls below 6°C. When the
temperature reaches 16°C, the boiler stops.

Note : This device works irrespective of any room thermostat
setting and will protect the complete heating system.

has a built in frost protection device that protects the

In case of power supply failure

The boiler no longer operates. As soon as power supply is
restored, the boiler will be automatically restarted.

Servicing and Maintenance

To ensure the continued efficient and safe operation of the
appliance it is recommended that it is checked and serviced as
necessary at regular intervals. The frequency of servicing will
depend upon the particular installation conditions and usage,
but in general once a year should be enough.

If this appliance is installed in a rented property there is a duty
of care imposed on the owner of the property by the current
issue of the Gas Safety (Installation and Use) Regulations,
Section 35.

Servicing/maintenance should be carried out by a competent
person in accordance with the rules in force in the countries of
destination.

To obtain service, please call your installer or Heatcall (Glow-
worm’s own service organisation) using the telephone number
behind the controls cover door.

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.

Cleaning

The boiler casing can be cleaned with a damp cloth followed by
a dry cloth to polish.

Do not use abrasive or solvent cleaners.

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.

7

2000225000B

1 Technical Data

Heating

Heat input (max) NET Q 25 kW

85,300 BTU/H

Heat input (min) NET Q 10,4 kW

35,490 BTU/H

Heat output (max) NET P 23 kW

78,480 BTU/H

Heat output (min) NET P 8,7 kW

29,670 BTU/H
Efficiency - Sedbuk D 79,90%
Maximum heating temperature 87° C
Expansion vessel effective capacity 5 l
Expansion vessel charge pressure 0,5 bar
Maximum system capacity at 75°C 110 l
Safety valve, maximum service pressure 3 bar

Hot water

Heat input (max) NET Q 25 kW

85,300 BTU/H

Heat input (min) NET Q 10,4 kW

35,490 BTU/H

Heat output (max) NET P 23 kW

78,480 BTU/H

Heat output (min) NET P 8,7 kW

29,670 BTU/H
Maximum hot water temperature 63 °C
Minimum hot water temperature 35 °C
Specific flow rate (for 30°C temp rise) 11L/min.
Threshold flow rate 1,7 L/min.
Maximum supply pressure 10 bar
Minimum supply pressure 0,5 bar

Electrical

Electrical supply 230 V ~ 50Hz
Electrical rating 122 W fused at 3A
Level of protection IPX4D
Fuse rating 125mA

Natural Gas (G20)

Ø Burner injector 1,2 mm
Inlet pressure 20 mbar
Maxi. Burner pressure 12 mbar
Mini. Burner pressure 2 mbar
Gas rate maximum 2,64 m3/h

Combustion

Products outlet diameter 60 mm
Fresh air inlet diameter 100 mm
Combustion products values CO (52 ppm)

CO2 (6,40%)

NOx (92ppm)

82000225000B

1 Technical Data

Bypass fully shut

1

2

Open 1/4 turn

3

Open 1/2 turn

Open 1 turn

4

5

Open 2 turns

The 23c is delivered in three
separate packages:

• The boiler

• The fixing jig and hanging bracket

• The flue system

heating supply and return lines

Available pressure (kPa) between

(10 kPa = 1 m WG)

50

40

30

20

10

0 500 1000

Flow rate through heating system (I/h)

1

2

3

4

5

2 Dimensions

165

10086

Diagram 1.1

9699

Net lift weight (boiler only) 36 kg

Gross lift weight (boiler and packaging) 37 kg

Optional electro mechanical
clock timer shown fitted

9

320

Diagram 2.1

2000225000B

3 Heating System Design

• The 23c is compatible with any type of installation.

• Heating surfaces may consist of radiators, convectors or fan
assisted convectors.

• Pipe sectional areas shall be determined in accordance with
normal practices, using the output/pressure curve
(diagram 1.1). The distribution system shall be calculated in
accordance with the output requirements of the actual system,
not the maximum output of the boiler. However, provision shall
be made to ensure sufficient flow so that the temperature
difference between the flow and return pipes be less than or
equal to 20°C. The minimum flow is 500 l/h.

• The piping system shall be routed so as to avoid any air
pockets and facilitate permanent venting of the installation.
Bleed fittings must be provided at every high point of the
system and on all radiators.

• The total volume of water permitted for the heating system
depends, amongst other things, on the static head in the cold
condition. The expansion vessel on the boiler is pressurised at

0.5 bar and allows a maximum system volume of 110 litres for

4 Domestic Hot Water System Design

an average temperature of 75°C and a maximum service
pressure of 3 bar. This pressure setting can be modified at
commissioning stage if the static head differs. An additional
expansion vessel can be fitted to the system if required, see

diagram 8.2.

• Provision shall be made for a drain valve at the lowest point of
the system.

• Where thermostatic radiator valves are fitted, not all radiators
must be fitted with this type of valve, and in particular, where the
room thermostat is installed.

• In the case of an existing installation, it is ESSENTIAL that the
system is thoroughly flushed prior to installing the new boiler,
using a proprietary product such as Fenox or Sentinel. Contact
the product manufacturers for specific details.

3.1 Filling the system

A filling device is fitted to the boiler to initially fill the system and
replace water lost during servicing, see the relevant parts of

diagram 2 controls and lighting and diagram 8.2.

• Copper tubing or plastic Hep
hot water system. Unnecessary pressure losses should be
avoided.

• The flow restrictor must be fitted limiting the flow through the
boiler to a maximum of 10 l/min.

• The boiler will operate with a minimum supply pressure of 0,6
bar, but under reduced flow rate.

Best operating comfort will be obtained from a supply pressure
of 1 bar.

0 may be used for the domestic

2

4.1 Hard Water Areas

In areas where the water is 'hard', more than 200mg/litre, it is
recommended that a proprietary scale reducer is fitted in the
cold water supply to the boiler.

102000225000B

5 Boiler Schematic

1 - Fan.
2 - Air pressure switch.
3 - Heat exchanger.
4 - Overheat thermostat.
5 - Combustion chamber.
6 - Expansion vessel.
7 - Ignition electrode.
8 - Burner.
9 - Flame sense electrode.
10 - Pump.
11 - Heating thermistor.

12 - Ignition module.
13 - By-pass.
14 - Gas valve.
15 - Loss of water sensor.
16 - Domestic hot water thermistor
17 - Automatic air vent
18 - Domestic water flow sensor
19 - Filter cold water inlet
20 - Filling system
21 - Discharge safety valve (3bar)
22 - Heating filter
23 - Drain valve

A - Heating flow
B - Domestic hot water outlet
C - Gas
D - Cold water inlet
E - Heating return

9720

9321

11

Diagram 5.1

2000225000B

6 Boiler Location, Flue and Ventilation

If the appliance has to be stored for any length of time before
installation it should be kept in a safe place where it will not be
a hazard to persons or obstruct any access.

6.1 Clearances

The position of the boiler must be such that there is adequate
space for servicing.

The recommended clearances are:

20 mm either side of the boiler.

600 mm at the front of the boiler.

300 mm below the boiler.

25 mm above the flue elbow.

Note: The boiler must be mounted on a flat wall which is
sufficiently robust to take its weight when full, that is, 36 kg. If
in doubt, expert advice should be obtained, in the event of the
wall being found not suitable.

Note: It is permissible to install the boiler with smaller clearances
than those quoted above PROVIDING that adequate
consideration is given for Servicing/Repairs at a later date. If
any doubt exists, contact the Glow-worm's Technical Helpline

01773 828300.

The minimum acceptable spacings from the terminal to
obstructions and ventilation openings are shown in diagram

6.1.

The boiler must be installed so that the terminal is exposed to
the external air.

Should any doubt exist as to the permissible position of the
terminal, contact the Glow-worm's Technical Helpline 01773

828300.

6.2 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
to be central over the terminal.

Terminal guard type K3 supplied by:

Tower flue components Ltd.
Morley road
Tonbridge
Kent
TN9 1RA

6.3 Flue options

There are various flue systems to choose from as follows:

Telescopic horizontal flue pack, (rear only).

Standard horizontal flue pack, (left or right only).

Standard horizontal extended flue pack, for use with standard
horizontal flue pack.

Vertical flue pack.

Twin flue pack.

Extensions, 90° and 45° bends.

Flue options and accessories.

For detailed information refer to flue options guide for further
information, this is available from your nearest stockist.

6.4 Cupboard or compartment ventilation

The boiler can be fitted in a cupboard or compartment without
the need for permanent ventilation.

MINIMUM SITING DIMENSIONS FOR THE

POSITIONING OF FLUE TERMINALS MM

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 300

E FROM VERTICAL DRAIN PIPES AND

SOIL PIPES 300

F FROM INTERNAL CORNERS AND

EXTERNAL CORNERS 300

G ABOVE ADJACENT GROUND OR

BALCONY LEVEL 300

H FROM SURFACE FACING THE

TERMINAL 600

I FACING TERMINALS 1200

J FROM OPENING (DOOR/WINDOW)

IN CAR PORT INTO DWELLING 1200

K VERTICAL FROM A TERMINAL 1500

L HORIZONTALLY FROM A TERMINAL 600

A

A

F

G

UNDER CAR PORT etc.

2816

C

B,C

G

A

E

G

H,I

B,C

K

F

F

G

J

K

K

L

L

K

G

D

F

Diagram 6.1

122000225000B

7 Fixing Jig Pack

The fixing jig is made up as follows:
A - Heating return fitting with isolating valve (v).
B - Cold water inlet fitting with isolating valve (m).

The cold water inlet restrictor supplied with boiler is
fitted when the boiler is installed. Refer to Section 9.

C - Heating flow fitting with isolating valve (q).
D - Domestic hot water outlet.
E - Gas fitting.

LEFT
HAND

9897

SUPPORT
BRACKET

F

H

COPPER
CONNECTIONS
AND WASHERS

D

C

(5 OFF)

ISOLATING
VALVE
PLATE

q

A

E

B

m

J

v

Other components within the fixing jig pack.

F - Hanging bracket
G - wall template
H - copper connections
J - sealing washers and screws

H

1 Heating systems connections

- Pipe diameter 22mm
2 Hot water system connections

- Pipe diameter 15mm
3 Gas connection

- Pipe diameter 15mm

RIGHT
HAND

SCREW

SUPPORT
BRACKET

9717

THE FIXING JIG
SHOWN ASSEMBLED

G

Diagram 7.1

13

2000225000B

8 Piping System Installation

8.1 Fixing jig, see diagram 7.1

• Remove the contents of the fixing jig pack.

• Secure the left and right hand support brackets to the isolating
valve plate with the securing screws (2 OFF) supplied.

• Connect the five copper connections and sealing washers to
the isolating valves.

1 Heating system connections - Pipe diam. 22mm

2 Hot water system connections - Pipe diam. 15mm

3 Gas connection - Pipe diam. 15mm

10038

165mm

8.2 Wall template

• Remove the wall template, follow the instructions given on the
wall template.

• Note: It is important the hanging bracket and service cock
bracket are fitted to a flat and true wall area for correct alignment
with the boiler. If this cannot be achieved it is acceptable to pack
out the service cock bracket to obtain the correct alignment.

• Position the wall template, see diagram 8.1.

• Mark the position of the holes for the hanging bracket and jig.

• Drill, plug and fix the hanging bracket to the wall using suitable
screws (not supplied).

• Check that the hanging bracket is level.

• Drill plug and fix the fixing jig to the wall.

• For horizontal flue system, mark the position for the flue hole
as follows:

8.3 Flue to rear of boiler

• Mark correct position of hole from template.

8.4 Flue to side of boiler

• Mark the horizontal centre line for the hole on the rear wall.
Extend the horizontal centre line to the side wall and mark the
vertical centre line of flue hole as shown in diagram 8.1.

8.5 Cutting the flue hole

• Making allowance for the slope of the flue, cut hole in external
wall, preferably using a core drill. For installations with internal
and external access use a 105 mm diameter core drill.

For installations with internal access only use a 125 mm
diameter core drill.

9898

Boiler

Filling device

20mm

MIN.

Diagram 8.1

Additional
expansion
vessel
(if required)

Domestic

water

Hot water out

Cold supply in

Important

When cutting the flue hole and when extending the flue centre
line to a side wall, remember that the flue system must have a
fall of about 35 mm per metre of flue DOWNWARD towards the
terminal. There must NEVER be a downward incline towards
the boiler.

8.6 Water connection

Connect the system pipework to the copper connections on the
fixing jig observing the correct flow and return format as shown
in diagram 8.2. Do not subject the isolating valves to heat.

8.7 Gas connection

• The supply from the governed gas meter must be of adequate
size to provide a constant inlet working pressure of 20 mbar (8
in w.g.).

Refer to

*

Section 14

Control

Drain
point

142000225000B

valve

*

Bypass

valve

Flow

Heating
circuit

Return

Diagram 8.2