Glow-worm 60BF User Manual

Instructions for Use

Installation and Servicing

T o be left with the user

Hideaway

60B

G.C. No. 41 313 12

221693B.12.00

0863

Balanced Flue Boiler

BS 6332
BS 5258

This is a Cat I2H Appliance

Reference in these instructions to British Standards and Statutory

Regulations/Requirements apply only to the United Kingdom.

The instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee Registration

For Ireland the rules in force must be used.

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 First Year Guarantee.

In the centre pages are to be found your Guarantee Registration Card, which we recommend you complete and

return as soon as possible.

If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer

Service number 01773 828100.

Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:

✔

All replacement parts

❏

✔

All labour charges

❏

All call-out charges

✔

❏

One Contact Local Service

REGISTER YOUR GLOW-WORM APPLIANCE

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0208 247 9857

Customer Services:
Tel: [phone]
Fax: [phone]

Nottingham Road, Belper, Derbyshire. DE56 1JT

Tel: [phone] Fax: [phone]

Hepworth Heating Ltd.,

General/Sales enquiries:

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, see Section 1.3.

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/productioncertifiedby: Notified body 0086.
The CE mark on this appliance shows compliance with:

1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels.

2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed
for use within certain voltage limits.

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

INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.

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

CERAMIC FIBRE/INSULATION PADS, GLASSYARN.

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

THERMOSTATS

These contain very small amounts of xylene in the sealed phial and capillary. If broken, under normal circumstances the fluid does
not cause a problem, but in case of skin contact, wash with cold water. If swallowed drink plenty of water and seek medical attention.

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

Introduction 3
Lighting the Boiler 4

General Data 1 5
Water Systems 2 7
Flue and Ventilation 3 8
Installation 4 10
Casing Location / Fitting 5 12
Electrical Wiring 6 14
Commissioning 7 15

SERVICING

INSTRUCTIONS

221693B

Servicing 8 17
Replacement Parts 9 19
Fault Finding 10 21
Spare Parts 11 24

2

Instructions for Use

Notes and General Information

Please read these instructions and follow them carefully for the
safe and economical use of your boiler.

The boiler is automatic in operation, once the pilot has been lit
and the controls set.

Glow-worm Hideaways are central heating boilers, to provide
heating and if required, an indirect domestic hot water supply.

Gas Safety (Installation and Use) Regulations

In your own interests and that of safety, it is the law that ALL gas
appliances are installed by a competent person in accordance
with the current issue of the above regulations.

Warning

Make sure that nothing obstructs the rear side grille or
clearances. See page 4 for minimum clearances.

PIEZO
IGNITION
BUTTON 'C'

THERMOSTAT
CONTROL
KNOB 'B'

GAS CONTROL
KNOB 'A'

5993

Boilers Installed in a Compartment

If the boiler is fitted in a compartment, cupboard etc., do not
obstruct the purpose built compartment vents or the grille on the
boiler.

Do not use the compartment for storage purposes.

Maintenance

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

It is the law that servicing must be carried out by a competent
person.

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.

To obtain service please call your installer or Heatcall (Glow­worm’s own service organisation) using the telephone number
given on the inside of the front panel.

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.

SETTING
POINTS

GAS CONTROL KNOB

OFF
PILOT / IGNITION
MAIN BURNER

E

60 BALANCED FLUE

Diagram 1

Boiler Electrical Supply

WARNING. This boiler must be earthed.
The boiler must only be connected to a 240V~50Hz supply

protected by a 3A fuse, maximum.
All wiring must be in accordance with the current issue of

BS7671.
Heat resistant flexible cable having a conductor size of 0.75mm

to the current issue of BS6500 Table 16 must be used.

2

,

3

221693B

Instructions for Use

To Connect an Electrical Plug

The standard colours of three core flexible cable are,
Brown - live, Blue - neutral, Green and Yellow - earth.
As the markings on your plug may not correspond with these

colours, continue as follows:
The Blue cable must be connected to the terminal marked “N”

or “Black”.
The Brown cable must be connected to the terminal marked “L”

or “Red”.
The Green and yellow cable must be connected to the terminal

marked “E” or “Green” or the earth symbol

.

To Light the Boiler

WARNING. If the pilot light goes out for any reason, do not
attempt to relight until 3 minutes have elapsed.

Remove the door by pulling forwards with the fascia at the top.
Lift up to disengage from the bottom side lugs.

Refer to diagram 1 to identify controls.
Check that the mains electrical supply to the boiler is switched

OFF.
Push in slightly and turn gas control knob “A” clockwise until

is against its setting point.
Turn thermostat control knob “B” anticlockwise until “O” is

against its setting point.
Push in slightly and turn gas control knob “A” anticlockwise until

is against its setting point, then depress fully and hold in.

Push in and release piezo ignition button “C” until the pilot
burner lights.

Air may be present in the supply pipe so the lighting of the pilot
may need to be repeated until all the air has been expelled.

When the pilot is alight, view through window “E”, keep gas
control knob “A” fully pushed in for about 15 seconds, then
release.

If the burner fails to stay alight, wait 3 minutes, then repeat the
lighting procedure only now keep control knob “A” pushed in for
a little longer before releasing.

Press in and turn gas control knob “A” anticlockwise until
against its setting point.

If the gas control knob “A” is turned to a safety lock prevents
it being turned on again for a short period. No attempt should

be made to relight the pilot until 3 minutes have elapsed.
Make sure that the pilot is alight and stable then switch on the

electrical supply.
Set any system controls to “ON” or “HIGH”.
Turn the boiler thermostat knob “B” clockwise until “MAX” is

against its setting point and the main burner will light. Adjust
thermostat to required setting between “MIN” and “MAX”.
“MAX” is about 82

Refit the door by locating the hooked runner at the bottom into
the slot in the side panels and pushing onto the studs.

o

C (180oF).

To Turn the Boiler Off

For short periods, turn the boiler thermostat control knob “B”
anticlockwise to “O”. The pilot will stay alight. To relight the
main burner turn thermostat control knob “B” clockwise to the
desired setting between “MIN” and “MAX”.

For longer periods, depress slightly and turn gas control knob
“A” fully clockwise until
thermostat control knob “B” anticlockwise to “O”. Isolate the

boiler from the electrical supply. Follow full lighting procedure
to relight. Refer also to “Protection Against Freezing”.

is against its setting point. Turn

Gas Leak or Fault

If a gas leak fault exists or is suspected the boiler must be turned
off, including the electrical supply and must not be used until the
fault has been put right. Advice/help should be obtained from
the local gas undertaking or your installation/servicing company.

Protection Against Freezing

If the boiler is to be out of use for any period of time during severe
weather conditions we recommend the whole system including
the boiler, be drained off to avoid the risk of freezing up. If an
immersion heater is fitted to the hot water cylinder make sure it
is switched off.

Sheet Metal Parts

WARNING. This boiler contains metal parts (components) and
care should be taken when handling and cleaning, with particular
regard to edges.

Cleaning

Keep the casing clean by wiping it occasionally with a damp
soapy cloth and dry with a polishing cloth.

Do not use abrasive cleaners.

Replacement Parts/Boiler Identification

If replacement parts are required apply to your local supplier.
Please quote the name of the boiler and its serial number which
can be found on the data label, positioned on the boiler top, to
the rear of the inclined flueway cleaning door.

Clearances

is

Minimum clearances must be left around the boiler as shown in
diagrams 1.3, 1.4 & 1.5.

221693B

4

General Data

✽ Refer to BOILER CASING
HEIGHT diagram

✝ A SPECIAL TOP CASING
TO SUIT 600mm (23

5

/

in.)

8

GAS CONNECTION

1

Rc

1

/

(

/

2

2

in. B.S.P.T.)

WATER CONNECTIONS

Rc1 (1in. B.S.P.T.)

WORKTOPS IS AVAILABLE

A

✝ F(MIN.)

G(MIN.)

H

C

✽

L

B

D

C

K

J

E

GENERAL DIMENSIONS - given in millimetres (Approx. inches)

WATER CONNECTIONS Rc1 reduced
with DISTRIBUTOR TUBE to

3

Rc

3

/

(

/

in. B.S.P.T.) (pumped return)

4

4

N

L

C

L

C

M

L

P

Diagram 1.1

0684

ABCDE✝FG H J K L M N P
mm 300 118 558 294 225 533 3 300 445 121 156 664 292 398
in. 113/445/822 111/287/821

Sheet Metal Parts

WARNING. When installing or servicing this boiler, care should
be taken to avoid any possibility of personal injury when
handling the edges of sheet metal parts.

Important Notice

This boiler is for use only on G20 gas.
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.

1.1 Data

Approximate weight of complete boiler : 79kg (174lb)
Water content : 5.76 litre (1.27gallons)
Gas connection : Rc1/2 (1/2in BSPT)
Water connection : Rc1 (1in BSPT)
Injector : 3.9mm
Electrical supply : 240V~50Hz, fused 3A
Burner : Aeromatic
All dimensions are given in millimetres (except as noted).
The Seasonal Efficiency Domestic Boilers UK (SEDBUK)

is 71.7%.
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

/8113/4171/243/461/8261/8111/2155/

1.2 Range Rating

This boiler is range rated and may be adjusted to suit individual
system requirements. The table gives settings and outputs.

The boiler input as supplied is preset to the maximum heat input
and should be adjusted to suit system requirements.

The indicator arrow should be stuck on the data label to indicate
the adjusted setting. The arrow is supplied in the loose items
pack.

RANGE RATING

NOMINAL
HEAT INPUT
(GROSS)

Btu/h

NOMINAL
HEAT
OUTPUT

BURNER

Btu/h
mbar

SETTING
PRESSURE

in.w.g

(HOT)

INJECTOR

kW

kW

min medium max

18.59 19.83 21.07

63,430 67,660 71,890

14.65 15.68 16.71

50,000 53,500 57,000

10.1 11.5 12.9

4.0 4.6 5.2

8

205750

5

221693B

General Data

1.3 Statutory Requirements

The installation of this must be carried out by a competent
person and must be in accordance with the relevant requirements
of the current issue of:

Manufacturer’s instructions, supplied.
The Gas Safety (Installation and Use) Regulations, Building

Regulations, Local Water Company Bye-laws, The Building
Standards (Scotland) Regulations, (applicable in Scotland),
Health and Safety at Work Act, Control of Substances Hazardous
to Health. The Electricity at Work Regulations and any applicable
local regulations.

Detailed recommendations are contained in the current issue of
the following British Standards and Codes of Practice,

BS6891, BS5546, BS5440 Parts 1 and 2, BS6798, BS5449,
BS6700, BS7478, BS7593, BS7671.

Manufacturer’s instructions must not be taken as overriding
statutory requirements.

1.4 B.S.I Certification

This boiler is certificated by B.S.I., for safety and performance.
It is, therefore, important that no alteration is made to the boiler
unless agreed, in writing, by Hepworth Heating Ltd.

Any alteration not approved by Hepworth Heating Ltd., could
invalidate the B.S.I. certification, boiler warranty and could
infringe the Statutory Requirements.

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 using the pressure drop
method and suitable leak detection fluid, purge in accordance
with the current issue of BS6891.

1.6 Electrical

WARNING. This boiler must be earthed.
The electrical installation must be carried out by a competent

person. All external components shall be of the approved type
and shall be connected in accordance with the current issue of
BS7671 and any local regulations which apply.

Connection of the boiler and any system controls to the mains
supply should be through an unswitched shuttered socket outlet
and 3A fused 3 pin plug, both to the current issue of BS1363.
Alternatively, a 3A fused double pole isolating switch may be
used, having a minimum double pole contact separation of
3mm, serving only the boiler and system controls.

2

Heat resistant cable of at least 75mm
current issue of BS6500 Table 16, must be used for all
connections within the boiler casing, to the control box, pump
etc.

(24/0.20mm), to the

0982

To
floor
level

MAX.900 (35

BOILER
WITH TOP
CASING

1

/

in.)

2

MID. 890 (35in.)
MIN. 860 (34in.)

MAX.
MID.

MIN.

FLOOR
LEVEL

BOILER CASING ALTERNATIVE
HEIGHT POSITIONS

MAX.
MID.

MIN.

BOILER CASING HEIGHT(S)

WORKTOP

BOILER

10

3

(

/

8

in.)

10

3

(

/

320 MIN.

5

(12

/

in.)

8

CUPBOARDS

MINIMUM CLEARANCES
LEVEL WITH WORKTOP

WORKTOP OR FIXTURE

3

10 (

/

in.)

3 (

CUPBOARD

10

3

(

/

in.)

8

BOILER

8

10

3

(

/

in.)

8

WITH

TOP

CASING

BOILER
WITHOUT
TOP CASING

MAX.867 (34
MID. 857 (33
MIN. 827 (32

320 MIN.
(12

BOILER

5

3

(

in.)

8

1

/

/

in.)

8

BOILER

WITHOUT

TOP

CASING

1

/

in.)

8

3

/

in.)

4

1

/

in.)

2

Diagram 1.2

5

/

in.)

8

in.)

16

Diagram 1.3

CUPBOARD

10

3

(

/

in.)

8

0866

0865

221693B

MINIMUM CLEARANCES
UNDER WORKTOP, FIXTURES

6

CUPBOARD

Diagram 1.4

1 General Data

1.7 Boiler Location

The casing can be fitted to the boiler at various heights. The top
casing can be discarded if preferred, when fitting the boiler
under a low worktop or fixture. Refer to diagram 1.2.

The boiler must stand on a level floor, conforming with local
authority requirements and building regulations.

The base temperature is within the requirements of the current
issue of BS5258. The boiler may stand on a wooden floor but
a metal base plate is required to protect plastic tiles and similar
floor coverings.

When the boiler is to be installed level with work surfaces and
the like, minimum clearances should be provided as shown in
diagram 1.3. Work tops which overhang the cupboard sides,
almost in contact with the casing top, require a larger minimum
air gap. Flush sided fixtures require the same overall minimum
space but can have a reduced air gap on one side.

Boilers to be installed under work tops or fixtures, with or without
the casing top fitted should be positioned to provide minimum
clearances as shown in diagram 1.4. To facilitate minimum
clearances it may be necessary to modify kitchen units and
fixtures.

A front access clearance should be provided as shown in
diagram 1.5.

The boiler may be installed in any room, although particular
attention is drawn to the requirements of BS7671 with respect
to the installation of a boiler in a room containing a bath or
shower. Any electrical switch should be so positioned that it
cannot be touched by a person using the bath or shower. The
electrical provisions of the Building Standards (Scotland)
Regulations apply to such installations in Scotland.

Where the installation of the boiler will be in an unusual location,
special procedures are necessary the current issue of BS6798
gives detailed guidance on this aspect.

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 features of cupboard or compartment
design are given in the current issue of BS6798.

1.8 Heating System Controls

The heating system should have installed: a programmer and
room thermostat controlling the boiler.

Thermostatic radiator valves may be installed in addition to the
room thermostat.

Note: For further information, see The Building Regulations
1991 - Conservation of fuel and power, 1995 edition - Appendix
G, table 4b.

BOILER

700 (27

WALL OR
FIXTURE

FRONT CLEARANCE

1

/

in.)

2

Diagram 1.5

0906

2 Water Systems

2.1 Water Pressure Head

The boiler shall only be connected to a cistern water supply with
a minimum head of 1metre (3ft3in) and a maximum head of
27metres (90ft) which has an open vent in the system.

The working pressure must be within the range 0.1bar to 2.7bar
(1.3 to 39lbftin

The boiler MUST NOT be connected to a sealed water system.

2.2 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 in the system, contact should be
made with the inhibitor manufacturers so that they can
recommend their most suitable product.

When using in an existing system take care to drain the entire
system, including the radiators, then thoroughly cleaning out
before fitting the boiler whether or not adding an inhibitor.

2

).

REFER TO BS 5546

22mm VENT

15mm COLD FEED

INDIRECT
CYLINDER

27metre
Max.

28mm

PUMP

BOILER
C

L

To Heating
Circuit

DRAIN OFF
COCK

7

Distributor tube in
pumped return
connection

Diagram 2.1

0869

221693B

2 Water Systems

2.3 Gravity Domestic and Pumped Heating

It is recommended that a cylinder thermostat is used to prevent
the stored water temperature becoming unnecessarily high
when the central heating pump is off.

The domestic primary flow and return must be 28mm o.d. The
installation must comply with the current issue of BS5546 and
BS6700, see diagram 2.1.

If the above conditions cannot be met, it is suggested that a fully
pumped system be used.

2.4 Pumped Heating and Hot Water

Where a single flow and return is taken from the boiler, a
minimum static head of 1metre (3ft3in) must be provided
between the water line of the cistern and the centre of the
waterway, see diagram 2.2.

2.5 Circulation Pump

Normally the pump should be set to give a temperature difference
of 11oC (20oF) across the boiler. At the appropriate pumped flow
rate the pressure loss through the boiler can be found from the
graph, diagram 2.3.

Use a pump with integral valves or fit isolating valves as close
to the pump as possible.

Note: If the pump is to be fitted inside the boiler casing a heat
shield kit is required. Kit No. 425837.

22mm VENT

15mm
COLD FEED

1 metre
MIN.
27metres
MAX.

PUMP

BOILER
C

DRAIN OFF
COCK

Distributor tube in
pumped return
connection

FULLY PUMPED SYSTEM
(DIAGRAMMATIC)

FLOW RATE (GALLON/MINUTE)

0123456

800
700

TO INDIRECT
CYLINDER

L

To Heating
Circuit

Diagram 2.2

32
28

0870

0872

2.6. Cylinder

For all systems supplying domestic hot water the cylinder must
be indirect.

2.7 Safety Valve

A safety valve need not be fitted to an open vented system.

2.8 Draining Tap

A draining tap must be provided at the lowest points of the
system which will allow the draining of the entire system,
including the boiler and hot water cylinder.

Draining taps should be to the current issue of BS2879.

3 Flue and Ventilation

3.1 Flue

Detailed recommendations for flues are given in the current
issue of BS5440 Part 1.

The boiler must be installed so that the flue terminal is exposed
to the external air. It is important that the position allows the free
flow of air across it at all times.

3.2 Terminal Positioning

The minimum acceptable spacings for the terminal to
obstructions, other terminals and ventilation openings are given
in diagram 3.1.

Car port or similar extensions of a roof only, or roof and one wall,
require special consideration with respect to openings, doors
and windows under the roof. Care is required in protecting the
roof if made from plastic sheeting. Seek further advice if the car
port consists of a roof and two or more walls from the local gas
undertaking.

600
500
400
300
200

WATER PRESSURE LOSS

(mm HEAD OF WATER)

100

0

4

0

FLOW RATE (LITRES/MINUTE)

812

16 20 24 28

PRESSURE LOSS OF BOILER

Where the terminal is within 850mm (34in) below plastic guttering,
an aluminium shield 1.5metres (5ft) long should be fitted to the
underside and immediately beneath the guttering.

The air inlet and products outlet duct and the terminal of the
boiler must not be closer than 25mm (1in) to combustible
material.

24
20
16

12

8

WATER PRESSURE LOSS

4
0

Diagram 2.3

(INCHES HEAD OF WATER)

3.3 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.

221693B

8

3 Flue and Ventilation

3.4 Protecting the Terminal

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 guard is available from

Tower Flue Components Ltd.,
Morley Road
Tonbridge,
Kent
TN9 1RA

quoting reference type “F”

3.5 Wall Thickness

Check the wall thickness where the boiler is to be fitted.
Flues available are:

Standard Pack,

part No.424604, 280 to 410mm (11 to 16in).

Short Pack,

part No. 424638, 150 to 280mm (6 to 11in).

Extension Kit,

part No. 424680 + standard pack, 410 to 610 (16 to24in).

3.6 Room Ventilation

The boiler is room sealed and does not require the room or
space containing it to have permanent air vents.

3.7 Cupboard and Compartment Ventilation

Where the boiler is fitted in a cupboard or compartment, the high
and low level permanent air vents must have effective areas in
accordance with "Compartment Air Vent Table".

Both the high and low level air vents must communicate with the
same room or must both be on the same wall to outside air.

A

A

F

G

Under Car Port etc.

B,C

G

A

E

G

H,I

B,C

K

F

F

G

J

C

K

L

L

K

G

D

F

K

MINIMUM SITING DIMENSIONS FOR
BALANCED FLUE TERMINALS

POSITION MINIMUM

SPACING

A DIRECTLY BELOW AN OPENABLE mm

WINDOW, AIR VENT, OR ANY
OTHER VENTILATION OPENING 300

B BELOW GUTTER,DRAIN/SOIL PIPE 300
C BELOW EAVES 300
D BELOW A BALCONY OR CAR PORT 600

E FROM VERTICAL DRAIN PIPES

AND SOIL PIPES 75

F FROM INTERNAL OR EXTERNAL

CORNERS 600

G ABOVE ADJACENT GROUND OR

BALCONY LEVEL 300

H FROM A SURFACE FACING

THE TERMINAL 600

I FACING TERMINALS 600
J FROM OPENING (DOOR/WINDOW)

IN CARPORT INTO DWELLING 1200

K VERTICAL FROM A TERMINAL 1500
L HORIZONTALLY FROM A TERMINAL 300

1112

COMPARTMENT
VENTILATION
REQUIREMENTS

VENTILATION
FROM ROOM
OR SPACE

FROM
OUTSIDE

9

Diagram 3.1

COMPARTMENT AIR VENT TABLE

HIGH LEVEL LOW LEVEL

VENT AREA VENT AREA

205cm232in2205cm232in

103cm2 16in2103cm216in

2

2

221693B

4 Installation

Before fixing the boiler make sure that the location selected is
in accordance with the requirements of Section 1.7.

4.1 Unpacking

The boiler casing panels are packed separately within the main
carton and are designed to enable gas and water connections
to be made before fitting the casing panels.

The casing brackets, distributor tube an loose items, in a plastic
bag, are packed in the top fitment.

4.2 Casing Brackets

Fit the two upper and two front casing brackets shown in
diagram 4.1. using eight of the No.8 screws.

Push the captive nuts, supplied loose, on to the casing brackets
as shown in diagram 4.1.

4.3 Water Connections - Gravity Domestic and
Pumped Heating

Fit suitable fittings into the boiler tappings, see diagram 4.2.
Connect pipework into prepared fittings ensuring that all pipes

are taken backwards and will clear the casings, see diagram

1.1.
Heating flow: Any one connection of the upper four may be

used.
Gravity domestic flow: Any one connection of the remaining

upper connections may be used.
Heating return: The distributor tube MUST be fitted into either

one of the front lower connections on ALL installations, see
diagram 4.3. The distributor tube is packed in the top carton
fitment.

Gravity domestic return: Any one connection of the three
remaining lower connections may be used for the gravity
domestic return.

When the front connections are used it is essential that any
pipework or fittings do not stick out more than shown in diagram

4.6.
If only limited space is available, it is recommended that the

front connections are used.
Fit plugs into unused tappings.
Do not route and pipes across the front of the boiler thermostat

pocket, controls or the combustion chamber cover.
Pipework must not be routed directly below the draught diverter,

across the boiler, but may be routed under the edges of the
draught diverter.

4.4 Water Connections - Fully Pumped
Systems

It is important that all connections are made as shown in
diagram 4.4.

Fit suitable fittings into the boiler tappings as required, see
diagram 4.4.

The water distributor tube MUST BE FITTED into the return
connection, see diagram 4.3.

Connect pipework into prepared fittings ensuring that all pipes
are taken backward and will clear the casings, see diagram 1.1.

When the front connections are used it is essential that any
pipework or fittings do not stick out more than shown in diagram

4.6.

UPPER CASING
BRACKET

CAPTIVE
NUT

CAPTIVE
NUT

No.8 SCREW (8)

FRONT
CASING
BRACKET

CASING BRACKETS FITTING

ALTERNATIVE

0873

HEATING OR
DOMESTIC
HOT WATER
FLOW

ALTERNATIVE
HEATING
RETURN
With distributor

GRAVITY

tube (not shown)

DOMESTIC
RETURN TO
ANY OF THE
3 REMAINING
LOWER CONNECTIONS

WATER CONNECTIONS - GRAVITY
DOMESTIC, PUMPED HEATING

Notch on DISTRIBUTOR
must lie within the shaded
area, BETWEEN TWO
MARKERS

DISTRIBUTOR TUBE

MARKERS

MUST BE IN PUMPED
RETURN CONNECTION

DISTRIBUTOR TUBE

0888

Diagram 4.1

Diagram 4.2

0871

Diagram 4.3

221693B

10

4 Installation

;;;

;;;

;;;

;;;

;;

If only limited space is available, it is recommended that the
front connections are used.

Fit plugs into unused tappings.
Do not route any pipes across the front of the boiler thermostat

pocket, controls or combustion chamber cover.
Pipework must not be routed directly below the draught diverter

across the boiler, but is allowed to be routed under the edges of
the draught diverter.

4.5 Pump in Boiler Casing

If the pump is to be fitted inside the boiler casing, see diagram

6.2, ensure that a heat shield kit is obtained and fitted
(Kit No. 425837).

The kit contains a flueway cleaning door with heat shield
(attached).

4.6 Balanced Flue Terminal
(Standard and short flue)

Mark out and cut a hole through the wall where the boiler is to
be installed, to the dimensions shown in diagram 4.5, after
checking that sufficient clearances will be left around the boiler
as described in Section 1.7.

Place the boiler in position. The balanced flue ducting will
project into the prepared hole in the wall.

Make a good seal around the boiler air duct on the inside wall.
Take the balanced flue assembly from its carton and remove the

four screws to release the outer baffle, see diagram 4.8.
Remove the four outer wire guards then pull off the inner baffle
and flue duct assembly.

Place the air duct assembly into the hole in the wall from the
outside, engaging it around the air duct on the boiler and sliding
it until the wall plate contacts the outer wall surface.

Seal the joint in the air ducts with the yellow tape provided. Tape
four pieces into the four inside corners, followed by four along
the joints, overlapping the corner pieces, to make a good seal.
Allow a minimum of 20mm (

Cement around the wall plate to make good and weatherproof.
Refit the inner baffle and flue duct assembly, sealing the joint

with the heat resistant semi-transparent tape provided.
Refit wire guards, outer baffle and secure with screws.

3

/4in) overlap of ductings.

BALANCED
FLUE DUCT
FROM BOILER

1

3 (

/

in.)

8

MIN.

PREPARED HOLE IN
THE WALL DIMENSIONS

240

1

(9

/

2

PREPARED
HOLE IN
THE WALL

in.)

360

1

(14

485
(19 in.)

Diagram 4.5

0876

/

in.)

4

WATER CONNECTIONS FULLY
PUMPED SYSTEMS

ALTERNATIVE
FLOW
POSITIONS

ALTERNATIVE
RETURN
POSITIONS
With distributor
tube (not shown)

Diagram 4.4

0874

11

VIEW ON ARROW 'A'

BOILER

57 MAX.
(2 1/4 in.)

PIPEWORK CASING
CLEARANCES

'A'

1524

57 MAX.
(2 1/4 in.)

Diagram 4.6

221693B

4 Installation

4.7 Boiler Connection

Connect the boiler to the system pipework.
Make the gas connection to the service cock, at the lower right

hand side of the boiler.

'B'

57 MAX.
(2 1/4 in.)

REAR CONNECTION
PIPEWORK (28mm)

VIEW ON
ARROW 'B'

BOILER

57 MAX.

FOR

(2 1/4 in.)

MINIMUM
CLEARANCE

Diagram 4.7

1525

BOILER
AIR DUCT

TERMINAL AND AIR DUCT ­STANDARD OR SHORT

AIR DUCT
ASSEMBLY

WALL
PLATE

WIRE
GUARDS

INNER BAFFLE/
FLUE DUCT
ASSEMBLY

OUTER
BAFFLE

0877

SCREW (4)

Diagram 4.8

5 Casing Location / Fitting

5.1 Vent Grille

One vent grille is supplied with the boiler, which can be fitted at
the rear of the left or right hand side casing. The grille is fitted
on the opposite side to any pipework connections.

Fit the grille, if required, to the side panel where no water pipes
are connected, as shown in diagram 5.1 prior to fixing the side
panel. The plastic pegs are a tight fit and are best pushed home
with a flat faced tool.

Discard the grille if the water connections are made on both
sides of the boiler or if the boiler is screened by fixtures.

221693B

5.2 Side Casings

Fit the side casings by locating their lugs into the appropriate
slot in the boiler plinth, see diagram 5.2, depending on the
required height, see Section 1.7

Secure the casing sides to the front upper brackets.

12

5 Casing Location / Fitting

5.3 Top Casing

Fit four plastic pegs into the appropriate holes in the top casing,
if being fitted, see diagram 5.3. The plastic pegs are a tight fit
and are best pushed home with a flat faced tool. The top casing
can be arranged to fit flush with or overhang the door. The top
casing is reversible to match, when level with, square or rolled
edge work surfaces.

Push the top casing on to all four side casing locations. From
inside the casing check that all rivets have located correctly.

For boilers fitted under work tops, not using the top casing, the
strap should be fitted using two No.8 screws, see diagram 5.4.

PLASTIC PEG

0885

PLASTIC PEG (4)

TOP CASING

A

SIDE
CASING

B

A

(L.H.)

PEG POSITIONS IN TOP CASING
A = FRONT EDGE FLUSH
B = 10mm (3/8 in) FRONT OVERHANG

AB

AB

0886

B

SIDE VENT GRILLE

MIN.

MID.

MAX.

No. 8 SCREW
(4)

SIDE
CASING
(L.H.)

MIN.

MID.

SIDE VENT GRILLE
(If required, will fit to
left or right side casing)

SIDE CASING
(R.H. SHOWN)

Diagram 5.1

UPPER
CASING
BRACKET

LOCATING
LUG AND SLOTS

0914

SIDE CASING

DOOR

BOILER SHOWN WITH
ROLLED EDGE FLUSH

AB

SIDE CASING

DOOR

BOILER SHOWN WITH
SQUARE EDGE FLUSH

TOP CASING FITTING

CAPTIVE
NUT

AB

Diagram 5.3

0909

SIDE CASING
(R.H.)

MAX.

FRONT
CASING
BRACKET

SIDE CASINGS FITTING

MAX.
MID.

MIN.

BOILER PLINTH

Diagram 5.2

STRAP fitted when no
top casing

STRAP FITTING (No top casing)

13

No.8 SECURING
SCREW

Diagram 5.4

221693B

6 Electrical Wiring

6.1 Control Box Cable Connection

WARNING. This boiler must be earthed.
Remove the screw and cover from the mains inlet connector,

supplied loose, see diagram 6.1.
Using heat resistant flexible cable of suitable length and rating

as in Section 1.6, connect the three cables to the required
terminals in the connector. Secure the outer sheathing with the
cable clamp.

Engage slots and lugs, replace cover and secure with screw.
Connect the mains inlet connector to the control box and use

three of the cable clips, supplied loose, pushed on to the edge
of the left hand panel in positions “CB” as shown in diagram 6.2
to ensure the cable does not make contact with any hot
surfaces.

6.2 Pump Cable Connection

Heat resistant cable with a rating as stated in Section 1.6 must
be used for all wiring near the boiler, including the pump if within
the boiler casing.

Support pump cable away from hot surfaces if within the boiler
casing by pushing two cable clips, supplied loose, on to the top
edge of one side panel, shown as “P” or “AP” in diagram 6.2.

6.3 System Controls

The electrical installation must be made according to the
current issue of BS7671.

The electrical isolator must isolate both the boiler and any
system controls.

6.4 Testing

Checks to ensure electrical safety should be carried out by a
competent person.

In the event of an electrical fault after installation of the boiler,
preliminary system checks must be carried out, that is, earth
continuity, polarity and resistance to earth, as described in the
British Gas Multimeter Instruction Book or similar publication.

CABLE
CLAMP

MAINS INLET
CONNECTOR

230 (9 in.)

CB

Fit 2 pump cable
clips at positions P

CB

P

25
(1 in.)

60

CB

(2 3/8 in.)

CABLE CLIP POSITIONS

COVER

L

E

N

SLOTS

LUGS

Diagram 6.1

P

AP

AP

230
(9 in.)

Alternative pump cable
clips (if feed is on the
right hand side) at
positions AP

Fit 3 control
box feed cable
clips at positions
CB

Diagram 6.2

0878

0904

221693B

14

7 Commissioning

Please ensure the “Benchmark” logbook is completed and left
with the user.

7.1 Commissioning and Testing the Boiler

The whole of the system should be thoroughly flushed out with
cold water with the pump removed. Make sure that all valves
are open. Refit the pump and fill the system. Examine for water
soundness and vent all air from the system, including the pump.

CAUTION: The following work should be carried out by a
competent person.

Identify the boiler controls by reference to diagram 7.1.
Check that the gas service tap “K” is closed, indicator line

horizontal.
Open all windows and put out any naked lights, pipes or

cigarettes.
Purge air from the gas supply in accordance with the current

issue of BS6891.
Make sure that the thermostat phial is positioned at the bottom

of the phial pocket “J” located by the washer being behind the
split pin.

See that the mains electrical supply is switched off.
Set thermostat control knob “B” to “O”.
Remove gas pressure test nipple screw “G” and fit a suitable

pressure gauge.
Turn gas control knob “A” to

push in. At the same time push and release piezo unit button
“C” until the pilot burner lights. At this stage air may be present
in the gas pipes and the lighting operation may need repeating.
When the pilot is alight, keep control button “A” fully pushed in

ignition and pilot position and

for about 15 seconds. If the pilot burner fails to remain alight,
repeat the lighting procedure but now keep the control button
pushed in for a little longer.

If the gas control knob “A” is turned to
prevents it being turned on again. No attempt should be made
to push in knob “A” until 3 minutes have elapsed.

Make sure that the pilot burner is alight and stable, see diagram

7.2 for flame dimensions, then switch the electrical supply on.
Set any remote controls for duty. Turn control knob “A” to main

burner position '
“MIN” and “MAX” opposite the setting point on the control box,

the main burner will then light, “MAX” is about 82oC (180oF).
Test for gas soundness around the boiler with a suitable leak

detection fluid.
Set the burner gas rate required ten minutes from lighting, see

page 2 for settings. Adjust screw “F”, diagram 7.1 to obtain the
required heat input. Turn anti-clockwise to increase. The
adjusting screw should then be sealed.

Should there be any doubt about the gas rate it should be
checked at the meter.

This should be in the range of 1.8 to 2.0m
These rates are for guide purposes, depending on the heat

setting.
Stick the self adhesive arrow indicator onto the data label

against the output the boiler is to be set to, the arrow is in the
fittings pack.

Check the operation of the flame failure device as follows: with
the main burner alight, turn gas control knob “A” fully anti-

clockwise to its stop '

'. Set thermostat control knob “B” between

', the main and pilot burners will go out.

, a safety lock

3

/h (63 to 71ft3/h).

B

L

A

G

0889

F

C

H

J

SETTING
POINTS

H

A GAS CONTROL KNOB J PHIAL POCKET
B TERMOSTAT CONTROL K GAS SERVICE COCK
C PIEZO IGNITION BUTTON L DATA LABEL

K

E

(Shown
closed)

E VIEWING WINDOW
F BURNER GAS RATE GAS CONTROL KNOB 'A'
ADJUSTMENT POSITIONS:­G BURNER PRESSURE
TEST POINT
H CONTROL BOX

= OFF

= PILOT/IGNITION
= MAIN BURNER

15

Diagram 7.1BOILER COMPONENTS

221693B

7 Commissioning

Relighting the boiler will not now be possible as a safety device
has been activated. After 60 seconds the flame failure device
should have closed, indicated by a click from the gas valve. Do
not attempt to relight until 3 minutes have elapsed.

Remove the pressure gauge and refit test nipple screw “G”.
Turn thermostat “B” to “O” then relight the pilot burner as the

relevant part of this Section.
Check that the boiler thermostat and all automatic controls are

working correctly.
Do not attempt to adjust the thermostat calibration screw.
Relight the main burner and check for gas soundness with a

suitable leak detection fluid.

7.2 Commissioning the System

Allow the system to heat up and set the pump adjuster to a
design position which gives a temperature difference of 11oC
(20oF) across the boiler.

There should be no undue noise in the system and no pumping
over of water or entry of air at the open vent.

Allow the system to reach maximum temperature and examine
for water soundness. The boiler should then be turned off and
the system drained as rapidly as possible to complete the
flushing process.

The system should then be filled again, vented and examined
for water soundness.

13 (1/2 in.)

FLAME

APPROX.

DIMENSION

PILOT
BURNER
ASSEMBLY

3-4mm
(1/8 in)

SPARK GAP
DIMENSION

PILOT FLAME DIMENSION

UPPER
HOOK

STUD
DOOR

FASCIA

1001

VIEWING
WINDOW

Diagram 7.2

0887

7.3 Completion

Instruct and demonstrate the efficient and safe operation of the
boiler and system.

Hand the Instructions for Use to the user for their retention,
making sure that they are understood.

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

It is the law that any servicing must be carried out by a
competent person.

Draw attention, if applicable, to the current issue of the Gas
Safety (Installation and Use) Regulations, Section 35, which
imposes a duty of care on all persons who let out any property
containing a gas appliance.

Reminder - Leave these instructions and the “Benchmark”
logbook with the user.

Fit the plinth front by locating the sides over the boiler plinth then
lowering to engage the upper and lower hooks, see diagram

7.3.
Fit the door by locating the hooked runner at the bottom into the

slots in side casings and push on to the studs on the side
casings, see diagram 7.3.

VIEW 1

LOWER
HOOK

VIEW 2

VIEW 1

VIEW 2

PLINTH / DOOR FITTING

PLINTH
FRONT

Diagram 7.3

221693B

16

8 Servicing

Servicing must be carried out by a competent person.
Before starting a service, turn off the gas supply at the service

cock, see diagram 8.1 and isolate the boiler from the electrical
supply.

Always test for gas soundness after completing a service or
replacement of parts.

8.1 Boiler Flueways

Pull door forward at the top to disengage studs and lift to release
from slots, see diagram 7.3.

Lift the plinth front up and forward to withdraw, see diagram 7.3.
Disconnect the union on the gas service cock, see diagram 8.1.
Remove the mains inlet connector by pulling upward, see

diagram 8.1.
Remove the retaining split pin on the thermostat phial pocket

then withdraw the phial and capillary, see diagram 8.2.
Remove the four screws retaining the combustion chamber

cover and burner assembly, see diagram 8.3. Withdraw
forward the complete assembly of cover, control box and
burner.

Remove the securing nut to release baffle tray and remove from
combustion chamber, taking care not to damage the insulation
material on the sides.

Remove the self-tapping screws which retain the cleaning door
and lift clear, see diagram 8.4.

Remove flueway baffles, see diagrams 8.5 and 8.6.
Place a sheet of paper in the combustion chamber to catch any

flue debris.
Thoroughly clean boiler flueways and fins with a suitable stiff

brush.
Replace in reverse order, after completing the relevant

instructions in Sections 8.2 and 8.3.
Make sure that the thermostat phial is at the bottom of its pocket

and located by the location washer being behind the retaining
split pin, see diagram 8.2. Make sure that there is clearance
between the thermostat capillary and the boiler.

THERMOSTAT
CAPILLARY

PHIAL
POCKET

SECURING THE
THERMOSTAT PHIAL

BAFFLE
TRAY

COMBUSTION
CHAMBER
COVER

ACCESS FOR SERVICING

1870

LOCATION
WASHER

RETAINING
SPLIT PIN

Diagram 8.2

0892

GRAPHITE
COATED
NUT

SECURING
SCREW (4)

Diagram 8.3

MAINS INLET
CONNECTOR
PULL UPWARD

GAS
SERVICE
COCK
UNION

ISOLATION OF
GAS AND ELECTRICITY

TURN
OFF

Diagram 8.1

0907

ACCESS TO FLUEWAY

17

0908

FLUEWAY
CLEANING
DOOR

SELF­TAPPING
SCREW (4)

Diagram 8.4

221693B

8 Servicing

8.2 Burner and Injector

Follow instructions to remove the cover, burner and controls
assembly as in Section 8.1.

Remove the two screws and nuts securing the burner support
bracket to the combustion chamber cover, see diagram 8.7.

Remove the graphite coated nuts on the supply feed pipe at the
rear of the burner to release the burner, take care not to damage
the pilot burner and shield when removing.

Clean burner thoroughly.
Check the main burner injector for blockage or damage and

replace if necessary, see Section 9.2 and diagram 8.8.

8.3 Service Checks

Inspect the pilot burner, thermocouple and clean or replace as
necessary. If necessary remove the pilot shield by removing the
securing screw and nut.

Check the condition of the side and rear insulation panels in the
combustion chamber.

Check the condition of the seals on the cleaning door and the
combustion chamber cover.

Replace all items in the reverse order, relight and test the boiler.

6122

FLUEWAY
BAFFLE

HEAT
EXCHANGERS

Diagram 8.6

FLUE
BAFFLE

6308

COMBUSTION
CHAMBER

MAIN

COVER

BURNER

BURNER
SUPPLY
PIPE

SCREW (2)

GRAPHITE
COATED
NUT (2)

MAIN
INJECTOR

REMOVAL OF BURNER FROM
COMBUSTION CHAMBER /
SUPPLY FEED PIPE

BURNER

BURNER
END CAP

6309

BURNER
SUPPORT
BRACKET

Diagram 8.7

6310

HEAT
EXCHANGERS

221693B

FLUEWAY
BAFFLE

Diagram 8.5

BURNER SERVICING

18

SECURING
NUT

WASHER

Diagram 8.8

9 Replacement of Parts

Before removing or replacing any parts, turn off the gas supply
at the gas service cock, see diagram 8.1 and isolate the
electrical supply to the appliance.

Always test for gas soundness after replacing any gas carrying
component.

9.1 Gas Valve

Follow relevant instructions in Section 8.1.
Remove control box cover by removing screw and unhooking at

the side, see diagram 9.1.
Disconnect electrical connectors, thermocouple nut and pilot

tube at the gas valve.
Remove the two screws which secure gas valve to control box.
Tilt control box to enable it to be lifted off the gas valve.
Unscrew the half union from gas valve.
Unscrew gas valve from burner supply pipe.
When screwing the pipe into the new valve use a little jointing

compound on the external thread only, to make a gas tight seal.
Replace thermostat phial as Section 8.1.
Reassemble in reverse order.
It will be necessary to purge the system of air after changing the

gas valve.
Relighting should be carried out as in Section 7.1.

9.2 Injector

When the burner has been removed from the injector manifold
as in Section 8.2 the injector can be unscrewed from the
manifold and renewed, as necessary.

When replacing use a little jointing compound on the external
thread only, to ensure a gas tight seal.

Replace in reverse order.
Replace thermostat phial as in Section 8.1.

9.3 Thermocouple

Remove the door and plinth as in Section 8.1
Disconnect thermocouple by unscrewing nuts at gas valve and

pilot burner, see diagrams 9.1 and 9.3. Release the cable clips
and the thermocouple can be withdrawn.

Reassemble in reverse order.

9.4 Pilot Burner

Follow instructions in Section 8.1 to remove cover and burner
controls assembly.

Disconnect the thermocouple nut at the pilot burner, see diagram

9.3.
Disconnect the nut retaining the pilot tube and injector in the

pilot burner.
Disconnect nut retaining electrode.
Remove the two screws and nuts securing the pilot burner and

shield to the front cover, see diagram 9.3.
Reassemble in the reverse order, checking that the spark gap

and pilot flame length are as shown in diagram 7.2.
Replace thermostat phial as in Section 8.1.

9.5 Boiler Thermostat

Follow relevant instructions in Sections 8.1 and 9.1.
Pull off the thermostat control knob.
Remove the two screws which secure the boiler thermostat to

the control box, see diagram 9.1.
Tilt the thermostat so that the electrical connectors can be

removed.
Withdraw boiler thermostat from control box complete with

capillary tube and phial attached.
Refer to diagram 9.2 when re-connecting.
Reassemble in the reverse order.
Replace thermostat phial as in Section 8.1.

MAINS INLET
CONNECTOR

THERMOSTAT
CONTROL
KNOB

THERMOSTAT
SECURING
SCREW (2)

PIEZO
UNIT

ELECTRICAL
CONNECTORS

IGNITION LEAD
(BLACK END)

CONTROL BOX

SLOT

GAS VALVE
SECURING
SCREW

BURNER
SUPPLY
PIPE

GAS
VALVE

PILOT
TUBE

GAS VALVE
SECURING
SCREW

ELECTRICAL
CONNECTORS

HALF UNION
PIPE

THERMOCOUPLE

6285

COVER
SECURING
SCREW

CONTROL BOX
COVER

Diagram 9.1

19

221693B

9 Replacement of Parts

240V~ 50Hz MAINS SUPPLY FUSED AT 3A

THERMOSTAT

L

N

C N/C

6124

GAS
VALVE

RED

ORANGE

GRN/YEL

BLUE

CHASSIS

CONTROL BOX WIRING

EARTH

9.6 Piezo Unit and Ignition Lead

Follow the relevant instructions in Section 8.1.
Pull off ignition lead at piezo unit, see diagram 9.1.
To replace lead also, pull off the lead at the spark electrode

terminal, see diagram 9.3.
Remove the control box cover by removing securing screw and

unhooking at the side, see diagram 9.1.
Remove the piezo unit, secured by a nut inside the control box.
Replace in reverse order.

9.7 Spark Electrode

Follow the relevant instructions in Section 8.1.
Disconnect the thermocouple nut and withdraw the thermocouple

from the pilot burner, see diagram 9.3.
Remove the spark electrode, secured by a nut.
Replace in reverse order, checking that the spark gap is as

shown in diagram 7.2.

9.8 Insulation Panels

Follow the relevant instructions in Section 8.1.
Remove the two screws retaining each side insulation panel

within the combustion chamber and remove panel, see diagram

9.4.
Release the rear insulation panel clips and lift out panel.
Replace in reverse order.
Replace thermostat phial as in Section 8.1.

SPARK
ELECTRODE

PILOT ASSEMBLY

REAR
INSULATION
PANEL

BAFFLE
TRAY

SECURING
SCREW (2)
AND NUT (2)

PILOT
INJECTOR

CLIP

Diagram 9.2

THERMOCOUPLE
NUT

IGNITION
LEAD
(CLEAR
END)

Diagram 9.3

SIDE
INSULATION
PANEL

0989

PILOT
TUBE
NUT

0897

221693B

GRAPHITE
COATED
NUT

INSULATION PANELS

20

SCREW

Diagram 9.4

10 Fault Finding - Electrical

Isolate electricity supply to the control box. Remove the control box cover and physically check all cables
and connections.

With electricity supply isolated, remove the cover of the mains inlet connector. Replace the connector without
cover. Restore electricity supply. Is voltage between C and N (blue) 220 to 240V ~ ?

Isolate electricity supply and re-connect red cable.
Restore the supply.

Isolate electricity supply to the control box.
Disconnect red cable at C. Restore electricity
supply. Is voltage between red cable connector
and N (blue) 220 to 240V ~ ?

Turn boiler thermostat to 'MAX'. Is voltage between
N/C and N (blue) 220 to 240V ~ ?

Faulty red cable or connection, isolate electricity
supply and renew cable.

Faulty thermostat, isolate electricity supply
and renew thermostat.

Faulty orange cable or connection, isolate
electricity supply and renew cable.

Faulty blue cable or connection, isolate electricity
supply and renew cable.

Faulty gas valve, isolate electricity
supply and renew valve.

Turn boiler thermstat to 'O'. Is voltage between N/C and
N (blue) zero ?

Isolate electricity supply. Disconnect orange cable at gas
valve. Restore electricity supply and turn boiler thermostat
to 'MAX'. Is voltage between orange cable connector and
N (blue) 220 to 240V ~ ?

Isolate electricity supply. Disconnect blue cable at gas
valve. Replace cover of mains inlet connector.
Restore electricity supply. Is voltage between orange
and blue cable connectors 220 to 240V ~ ?

Isolate electricity supply. Re-connect orange and blue
cables to gas valve. Restore electricity supply.
With pilot burner lit and boiler thermostat set between
'MIN' and 'MAX', does the main burner light?

Turn boiler thermostat to 'O'.
Does main burner extinguish?

Boiler controls in order.

START Carry out preliminary electrical checks to make sure that the electricity supply is available at the boiler.
Check that any remote time or temperature controls are calling for duty. Make sure that the system is filled,
the gas supply is available and the pilot is lit.

YES

NO

NO

NO

NO

NO

NO

NO

NO

NO

YES

YES

YES

YES

YES

YES

YES

10.1 Electrical

Refer to electrical fault finding chart, diagram 10.1, functional
flow diagram 10.2 and wiring diagram 9.2.

IMPORTANT: The preliminary electrical system checks as
contained in the British Gas Multimeter Instruction Book, or
similar publication, are the first checks to be carried out during
a fault finding procedure. On completion of the service fault
finding task which has required the breaking and remaking of
electrical connections, then the checks, earth continuity, polarity
and resistance to earth must be repeated.

L

THERMOSTAT

C

N/C

RED

FUNCTIONAL FLOW WIRING

ORANGE

GAS VALVE
CONTROL
SOLENOID

3

Diagram 10.2

0900

4

BLUE

N

0899

ELECTRICAL FAULT FINDING

21

Diagram 10.1

221693B

10 Fault Finding - Thermocouple

Disconnect appliance thermocouple from the multi-functional control. Check that all connections
are clean and in good condition. Fit test meter interrupter into the magnet unit. Fit appliance
thermocouple into the test meter interrupter.

Hold down control tap in ignition position. Ignite burner, allowing thermocouple to attain
operating temperature. Measure the OPEN CIRCUIT voltage.

Is
voltage
greater

than

15mV?

Note the open circuit reading then measure the CLOSED CIRCUIT voltage. Note this voltage.
Referring to the diagnosis graph, mark the open circuit voltage on the VERTICAL axis,
and the closed circuit voltage on the HORIZONTAL axis. Note the point where these
two values intersect on the graph.

YES

NO

Faulty thermocouple.
Replace.

0194

THERMOCOUPLE
CIRCUIT IS
SATISFACTORY

B

Faulty magnet unit in multi-functional
control. Replace.

which

area of the

graph is the

intersect

THERMOCOUPLE FAULT FINDING

10.2 Thermocouple

To test the thermocouple a meter with a range of 0 to 30mV is
required together with a thermocouple interrupter test unit
similar to the British Gas Minitest 6 Unit.

Refer to thermocouple fault finding chart, diagram 10.3 and
diagnosis graph, diagram 10.4.

10.3 Pilot

Refer to pilot fault finding chart, see diagram 10.5.

In

A

C

Faulty thermocouple.
Replace.

Diagram 10.3

29

1546

27
25
23
21
19

17

ABC

221693B

22

15

13
11

Open Circuit Voltage (millivolts)

9

0246810121416182022

Closed Circuit Voltage (millivolts)
DIAGNOSIS GRAPH FOR

THERMOCOUPLE CIRCUIT

Diagram 10.4

PILOT WILL NOT LIGHT
START HERE

Check gas line-open all cocks,
rectify any blockages, purge out
any air. Does pilot light?

NO

Apply match to pilot burner instead
of pressing piezo unit button.
Does pilot light?

NO YES

Undo tubing nut at pilot burner.
Turn gas valve knob to Pilot/Ign.
Press gas valve knob.
Does gas flow freely?

NO

YES

YES

10 Fault Finding - Pilot

Does pilot stay alight when
gas valve knob is released?

NO YES

PILOT SATISFACTORY

Does pilot flame envelop
thermocouple?

NO

0905

YES

Rectify blockage in pilot injector,
or renew pilot injector.

Undo tubing nut at pilot outlet
of gas valve. Press gas valve knob.
Does gas flow freely?

NO

Change blocked pilot tube.

Change gas valve.

YES

Check aeration. If necessary - Clean
pilot, rectify blockage in pilot
injector, or replace.

Check thermocouple circuit using
Thermocouple and Boiler Overheat
Cut-Off fault finding.

On pressing piezo unit button is
there a spark across electrode
gap?

NO

Pull ignition lead off electrode.
Hold end of lead close to pilot
burner and operate piezo unit.
Is there a spark across gap?

NO

Pull ignition lead off piezo unit.
Using blade of a screwdriver, touch
unit chassis and leave approx.
4mm gap from connection tag on
piezo unit. Operate piezo.
Is there a spark across gap?

NO

YES

YES

YES

Change
piezo unit.

Check electrode gap. Reposition,
or replace electrode as necessary.

23

Change
ignition lead.

Diagram 10.5BOILER PILOT FAULT FINDING

221693B

11 Spare Parts

The key number in the first column of the list will help identify
each part in diagram 11.1.

When ordering spare parts quote the part number and
description, stating the model and serial number off the data
label “L”, see diagram 7.1.

If ordering from British Gas the GC should be quoted.

1

3

4

6286

2

12

6

5

8

11

9

7

10

Diagram 11.1

Key No Part No. Description GC Part No.

1 425568 Electrical control box assembly 312 451
2 203329 Gas control valve 384 345
3 205750 Injector
4 203414 Pilot burner assembly 312 426
5 203508 Injector - pilot 395 674
6 202407
6 202415
7 202571 Thermostat c/w screws
8 FF2228 Control knob assembly 355 241
9 202700 Piezo unit 384 146
9 202702 Piezo unit 382 585
10 WW4613 Ignition lead 136 399
11 202605 Spark electrode 395 720
12 208302 Sight glass 312 419

}

Thermocouple c/w nut

392 934

Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.

221693B

24