Glow-worm Betacom 24, Betacom 30 Installation And Servicing Manual

Supplied By www.heating spares.co Tel. [phone]

982.160116/000 - 07.06

INSTALLATION AND SERVICING

Betacom

Betacom 24

G.C. No. 47-019-04

Betacom 30

G.C. No. 47-019-05

High Effi ciency

Combination

Boilers

Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT

www.glow-worm.co.uk

1

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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.

We recommend you complete and return as soon as possible

your Guarantee Registration Card.

If your guarantee registration card is missing

you can obtain a copy or record your registration

by telephoning the Glow-worm customer service number 01773 828100.

Customer Service:

01773 828100

Technical Helpline:

01773 828300

General and Sales enquiries:

Tel. [phone]

Fax: [phone]

To register your Glow-worm appliance

call:

0800 0732142

2

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The instructions consist of two parts, Installation and Servicing Instructions. The instruc-

tions 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.

CONTENTS DESCRIPTION SECTION PAGE

Warnings 4
Important Information 4

INTRODUCTION

General Information 5
Appliance Safety Devices 6
Maintenance and Servicing 6

Technical Information 1 7
Boiler Location and Ventilation 2 12
Flue Options and Terminal Clearances 3 13
Heating System 4 15
Domestic Hot Water System 5 17
Installation Preparation 6 17
Gas/Water & Appliance Connection 7 19

INSTALLATION

INSTRUCTIONS

Safety Discharge Valve and
Condensate Connection 8 20
Flue Preparation and Installation 9 22
Electrical Connection 10 34
Commissioning 11 36
Servicing 12 40
Fault Finding 13 43
Replacement of Parts 14 45
Spare Parts 15 47
Manual Handling 16 48

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WARNINGS

Gas Leak or Fault

Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e.smoking, blowlamps, hot

air guns etc. Do not operate electrical lights or switches either on or off. Open all doors and windows,ventilate the

area.

Sheet Metal Parts

This boiler contains metal parts (components) and care should be taken when handling and cleaning, with particular

regard to edges.

Sealed Components

Under no circumstances must the User interfere with or adjust sealed parts.

Important Information

Gas Category

This boiler is for use only on G20 natural gas or G31 propane
with the use of an appropriate kit.

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.

Testing and Certifi cation

This boiler is tested and certifi cated for safety and perform­ance. It is, therefore, important that no alteration is made to the
boiler, without permission, in writing, by Glow-worm.

Any alteration not approved by Glow-worm, could invalidate
the certifi cation, boiler warranty and may also infringe the cur­rent issue of the statutory requirements.

CE Mark

This boiler meets the requirements of Statutory Instrument,
No. 3083 The Boiler (Effi ciency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on
the effi ciency requirements for new hot water boilers fi red with
liquid or gaseous fuels.

Type test for purposes of Regulation 5 certifi ed by: Notifi ed
body 0087.

Product/production certifi ed by: Notifi ed 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 harmonisation of the Laws of
the Member States relating to electrical equipment de­signed for use within certain voltage limits.

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

Control of 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.

Electrical Supply

The boiler must be earthed.

All system components shall be of an approved type and all
wiring to current I.E.E. wiring regulations.

External wiring must be correctly earthed, polarised and in ac­cordance with the relevant standards.

In GB this is BS 7671.

In IE this is the current edition of I.S.813 “Domestic Gas Instal­lations”.

The boiler must be connected to a permanent 230V ac, 50Hz
supply.

Connection of the whole electrical system of the boiler, including
any heating controls, to the electrical supply must be through
one common isolator and must be fused 3 Amp maximum.

Isolation should be by a double pole switched fused spur box,
with a minimum gap of 3mm for both poles. The fused spur
box should be readily accessible and preferably adjacent to the
appliance. It should be identifi ed as to its use.

Alternatively connection can be made through an unswitched
shuttered socket and 3A fused 3-pin plug both to the current
issue of BS 1363, provided they are not used in a room contain­ing a bath or shower.

Wiring to the boiler must be PVC 85°C insulated cable, not less
than 0.75mm² (24/0.20mm).

IMPORTANT NOTE

ALL electrical connections to the boiler

must be permanently fi xed to a wall or a

sturdy support feature in a tidy manner.

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General Information

General Note

This boiler is designed for use as part of a sealed water cen­tral heating system with fully pumped circulation. The pump,
expansion vessel and associated safety devices are all fi tted
within the boiler.

Once the controls are set the boiler operates automatically.

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

Water Treatment

In the case of an existing system, it is ESSENTIAL that prior to
installing the new boiler the system is thoroughly fl ushed. For
optimum performance after installation of a new system, the
boiler and its associated central heating system should also
be fl ushed. Flushing should be carried out in accordance with
BS7593: 1992 using a cleanser such as Sentinel X300 or X400,
Fernox Restorer or Salamander corrosion guard cleaner.

For long-term corrosion protection, after fl ushing, a suitable in­hibitor should be used, refer to the current issue of BS 5449
and BS 7593 on the use of inhibitors in central heating sys­tems. Examples are Sentinel X100 Fernox Protector or Sala­mander corrosion guard inhibitor.

Compartment or Cupboard Installations

If the boiler is fi tted into a compartment or cupboard it does not
require ventilation openings.

Do not use the compartment or cupboard for storage.

Condensate Drain

The condensate drain, see diagram 8.2, must not be modifi ed
or blocked.

Pluming from fl ue terminal

Like all boilers with a fl ue heat exchanger, this appliance will
produce a plume of condensation from the fl ue terminal in cool
weather. This is due to the high effi ciency and hence low fl ue
gas temperature of the boiler. It is normal and not a fault indi­cation.

Electrical Supply

If the mains electricity and gas are to be turned off for any long
periods during severe weather, it is recommended that the
whole system, including the boiler, should be drained to avoid
the risk of freezing.

NOTE: Contact your installation/servicing company as drain­ing, refi lling and pressurising MUST be carried out by a com-

petent person.

Manual Handling

IMPORTANT: With regards to the “Manual Handling Opera-

tions, 1992 Regulations”, the appliance exceeds the recom­mended weight for a one man lift.

Clearances

If fi xtures are positioned close to the boiler, space must be
left as shown in diagram 2.1.

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Appliance Safety Devices

Electrical Supply Failure

The boiler will not work without an electrical supply.

Normal operation of the boiler should resume when the electri­cal supply is restored.

Reset any external controls, to resume normal operation of the
central heating.

If the boiler does not resume normal operation turn the mode
knob on
eration after this call your Installation/Servicing company.

position. If the boiler does not resume normal op-

Overheating safety

In the event of the boiler overheating the safety devices will
cause a safety shutdown. If this happens, turn the mode knob
on

position.

Safety Discharge Valve

A safety discharge valve and discharge pipe is fi tted to the
boiler. This valve must not be touched. Should there be any
discharge from the pipe, isolate the boiler electrical supply and
call your installer or Glow-worm’s own service organisation
using the telephone number on the inside front cover of this
booklet.

Frost protection

The appliance has a built in frost protection device that protects
the boiler from freezing. With the gas and electric supplies ON
and irrespective of any room thermostat setting, the frost pro­tection device will operate the pump when the temperature of
the boiler water falls below 5°C.

The burner will switch off when the temperature reaches 30°C.

Condensate Drain Blockage

As a safety feature the boiler will stop working if the condensate
drain becomes blocked. During freezing conditions this may be
due to the forming of ice in the condense drain external to the
house. Release an ice blockage by the use of warm cloths on
the pipe. The boiler should then restart. Contact your installa­tion/servicing company if the fault persists.

Maintenance and Servicing

Maintenance and Servicing

To ensure the continued effi cient 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.

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 Glow-worm’s
own service organisation using the telephone number on the
inside front cover of this literature.

Please be advised that the ‘Benchmark’ logbook, located at
back of literature, should be completed by the installation engi­neer on completion of commissioning and servicing.

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 specifi cation that we require. Do not use recon­ditioned or copy parts that have not been clearly authorised by
Glow-worm.

If a part is required contact Glow-worm’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 name badge on the front of the appliance.

If in doubt seek advice from the local gas company or Glow­worm’s own service organisation using the telephone number
on the inside front cover of this booklet.

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1 Technical Information

87

300

180

C

L

FLUE

400

84

BOILER

C

L

700

1.1 IMPORTANT

The boiler is supplied in one carton, which includes the appli­ance packs, see diagram 6.1.

The fl ue is supplied separately.

Where no British Standards exists, materials and equipment
should be fi t for their purpose and of suitable quality and work­manship.

The installation of this boiler must be carried out by a compe-
tent person in accordance the rules in force in the countries
of destination.

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

1.2 Statutory Requirements

In GB the installation of the boiler must be carried out by a
competent person as described in the following regulations:

The manufacturer’s instructions supplied.

The Gas Safety (Installation and Use) Regulations.

The appropriate Buildings Regulations either The Building
Regulations, The Building Regulations (Scotland),The Building
Regulations (Northern Ireland).

The Water Fittings Regulations or Water byelaws in Scotland.

Diagram 1.1

The Health and Safety at Work Act, Control of Substances Haz­ardous to Health (COSHH).

The Current I.E.E. Wiring Regulations.

Where no specifi c 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 following current issues of:

1) Central heating system specifi cation (CheSS)

and

2) Controls for domestic central heating system and hot wa­ter. BRECSU.

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1 Technical Information

1.3 Technical Data

All dimensions are given in millimetres (except as noted).

See diagrams 1.1 and Boiler Specifi cation table.

The data label is positioned on the base of the boiler.

Boiler specification Unit Betacom 24 Betacom 30

Gas category ll

Heating output at 80°C/60°C (Hi) kW 18.1 - 24.5 11.1 - 28.6
Efficiency calculated on net calorific value

% 94.9 - 95.8 95.2 - 97.1

at 80/60°C
Heating output at 50°C/30°C (P) kW 19.2 - 26.2 15.9 - 30.6
Efficiency calculated on net calorific value

% 101.1 - 102.2 100.5 - 103.8

at 50/30°C
Heat input (Hs) (heating) kW 21.08 - 28.4 17.76 - 32.74
Heat input (Hs) (DHW) kW 11.65 - 28.4 13.3 - 32.74
Maximum hot water temperature °C 83 83

2H3+

ll

2H3+

Heating

Heating temperature range C° 35 - 78 35 - 78
Expansion vessel, useful capacity l 8 8
Expansion tank initial pressure bar 1 1
Safety valve, maximum service pressure

(PMS)

bar 3 3

Domestic hot water

Hot water temperature range °C 30 - 55 30 - 55
Specific flow rate (D) (ΔT 25°C) l/min 14.0 16.4
Specific flow rate (D) (ΔT 30°C) l/min 11.7 13.7
Specific flow rate (D) (ΔT 35°C) l/min 10.0 11.7
Threshold flow rate l/min 3 3
Maximum supply pressure bar 6 6
Minimum operating pressure bar 0.8 0.8

Combustion

Product outlet flow rate g/s 15.9 16.4
Product outlet temperature °C 85 70
Values of product outlet (measured on nominal heating output with G20 reference gas):

CO ppm 38.0 54.8

CO2 % 6.40 7.20

NOx balance

mg/

kWh

163.1 122.0

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1 Technical Information

Boiler specification Unit Betacom 24 Betacom 30

Dimensions:

Height mm 700 700
Width mm 400 400
Depth mm 300 300
Net weight kg 41.5 43
Supply voltage V/Hz 230/50 230/50
Maximum absorbed power W 145 150
Electric protection IP X4D IP X4D
CE number 0694 BN 3710 0694 BN 3710

Technical data depending on the gas type
Natural gas G 20 (1)

Flow rate at maximum input

Flow rate at minimum input

Inlet pressure mbar 20 20
Burner injector diameter mm 1.25 1.30

m

m

3

/h

3

/h

2.71 3.12

1.11 1.27

(1) 15 °C, 1013,25 mbar

Burner pressure tables

Betacom 24

HEAT OUTPUT PRESSURE mbar

kW Btu/hr G20 G30 G31

9.5 32566 2.1 4.6 4.6
10 34120 2.3 5.0 5.1
11 37532 2.7 6.1 6.2
12 40944 3.2 7.2 7.5
13 44356 3.7 8.4 8.9
14 47768 4.3 9.7 10.4
15 51180 4.9 11.1 12.1
16 54592 5.5 12.5 13.9
17 58004 6.1 14.1 15.9
18 61416 6.8 15.7 18.0
19 64828 7.5 17.4 20.3
20 68240 8.2 19.2 22.7
21 71652 9.0 21.1 25.3
22 75064 9.8 23.1 28.0
23 78476 10.6 25.1 31.0
24 81888 11.4 27.2 34.1

24.5 83594 11.6 28.0 35.6

Betacom 30

HEAT OUTPUT PRESSURE mbar

kW Btu/hr G20 G30 G31

11.1 37832 2.2 4.0 4.0
12 40944 2.6 4.8 4.9
13 44356 3.0 5.8 6.0
14 47768 3.4 6.7 7.0
15 51180 3.9 7.7 8.1
16 54592 4.4 8.7 9.3
17 58004 4.9 9.7 10.5
18 61416 5.5 10.8 11.9
19 64828 6.1 12.0 13.3
20 68240 6.7 13.2 14.9
21 71652 7.3 14.5 16.5
22 75064 7.9 15.8 18.3
23 78476 8.6 17.2 20.1
24 81888 9.3 18.6 22.1
25 85300 10.0 20.0 24.1
26 88712 10.8 21.5 26.3
27 92124 11.5 24.6 30.9
28 95536 12.3 26.3 33.4

28.6 97735 12.7 27.5 35.5

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1 Technical Information

1.4 Gas Supply

The gas installation must 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 fl uid, purge
in accordance with the above standard.

1 Drain valve

2 Pressure gauge

3 By-pass

4 Pump

5 Heating system safety valve 3 bar

6 Expansion vessel

7 Overheat thermostat

8 Condense syphonic trap

9 Automatic air vent

10 Recuperator

11 Flue overheat safety thermostat

12 Air pressure switch

13 Fan

14 Flue hood

15 Primary heat exchanger

16 Burner

17 Thermistor

18 Hydraulic 3-way valve

19 Water valve

20 Domestic plate to plate

heat exchanger

21 Gas valve

22 Low pressure sensor

1.5 Condensate Drain

A plastic drain pipe must be fi tted to allow discharge of conden­sate to a drain.

Condensate should, if possible, be discharged into the internal
household draining system. If this is not practical, discharge
can be made externally into the household drainage system or
a purpose designed soak away, see section 8 for more details.

FLUE

CONDENSE

WARNING: This
schematic is for in­formation only.

11

RETURN

HEATING

FLOW

OUTLET

DOMESTIC

WATER

GAS

INLET

Diagram 1.2

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2 Boiler Location and Ventilation

2.1 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.

This boiler is suitable for installation in bathroom zones 2 and 3.

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.

2.2 Clearances

The boiler should be positioned so that at least the minimum
operational and servicing clearances are provided, see dia­gram 2.1.

Additional clearances may be benefi cial around the boiler for
installation and servicing.

For fl ue installations where external access is not practicable,
consideration should be given for the space required to insert
the fl ue internally, which may necessitate clearance larger than
those specifi ed in diagram 2.1.

5

5

006

051

5

5050

2.3 Timber Frame Buildings

If the boiler is to be installed in a timber frame building it should
be fi tted in accordance with the Institute of Gas Engineers doc­ument IGE/UP/7/1998. If in doubt seek advice from local gas
undertaking or Glow-worm.

2.4 Room Ventilation

The boiler is room sealed so a permanent air vent is not re­quired.

2.5 Cupboard or Compartment Ventilation

Due to the high effi ciency and hence low casing temperature of
this boiler, cupboard or compartment ventilation is not neces­sary.

Leave existing air vents.

200

A removable compartment door
can be placed a minimum of 15mm

Diagram 2.1

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3 Flue Options and Terminal Clearances

Top horizontal telescopic fl ue Ø60/100
Part No. A2043600

Twin Flue

Twin Flue Adapter, concentric fl ue Ø80
Part No. A2011000

Top horizontal standard fl ue Ø60/100
Part No. A2043400

Flue Accessories

Black Horizontal Terminal Kit, for use with
A2043500; A2043600; A2043400
Black Horizontal Terminal Kit,
concentric fl ue Ø60/100 - Part No. A2043700

Plume Management Kit, for use with
A2043500; A2043600; A2043400
Plume Management Kit, basic set, white,
concentric fl ue Ø60/100 - Part No. A2044100
1m extension, white - Part No. A2044300

o

87

elbow, white - Part No. A2044700

o

45

bend (2), white - Part No. A2044500
Plume Management Kit, basic set, black,
concentric fl ue Ø60/100 - Part No. A2044000
1m extension, black - Part No. A2044200

o

87

elbow, black - Part No. A2044600

o

45

bend (2), black - Part No. A2044400

Concentric Flue Ø60/100 accessories:
2 metre extension kit, concentric fl ue
Ø60/100 - Part No. 2000460483
1 metre extension kit, concentric fl ue
Ø60/100 - Part No. 2000460482

0.5 metre extension kit, concentric fl ue
Ø60/100 - Part No. 2000460481
Adjustable fl ue pipe 0-50mm kit,
concentric fl ue Ø60/100 - Part No. 2000460487

o

90

fl u e elbow pack,
concentric fl ue Ø60/100 - Part No. 2000460484

o

45

fl u e bend pack,
concentric fl ue Ø60/100 - Part No. 2000460485
Flue support clips (3),
concentric fl ue Ø60/100- Part No. A2043900

Vertical Flue

Vertical Flue Adapter, concentric fl ue Ø60/100
Part. No. A2024600
Vertical fl ue terminal kit, concentric fl ue Ø60/100
Part. No. 2000460480

13

Diagram 3.1

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3 Flue Options and Terminal Clearances

HORIZONTAL FLUES

A DIRECTLY BELOW AN OPENING, AIR BRICK,
OPENING WINDOWS 300
B ABOVE AN OPENING, AIR BRICK,
OPENING WINDOWS 300
C HORIZONTALLY TO AN OPENING,
AIR BRICK, OPENING WINDOWS 300
D BELOW GUTTER, DRAIN/SOIL PIPE 25
E BELOW EAVES 25
F BELOW A BALCONY OR CAR PORT 25
G FROM VERTICAL DRAIN PIPES AND
SOIL PIPES 25
H FROM INTERNAL/EXTERNAL CORNERS 25

* TO A BOUNDARY ALONGSIDE THE

H
TERMINAL 300
I ABOVE ADJACENT GROUND OR
BALCONY LEVEL 300

J* FROM SURFACE OR A BOUNDARY
FACING THE TERMINAL 600
K FACING TERMINALS 1200
L FROM OPENING (DOOR/WINDOW)
IN CAR PORT INTO DWELLING 1200
M VERTICAL FROM A TERMINAL 1500
N HORIZONTALLY FROM A TERMINAL 300

3.1 Flue Options

There are various fl ue options to choose from as illustrated in
diagram 3.1. The fl ue lengths and installation are described in
section 9.

3.2 Flue Terminal Position

The minimum acceptable siting dimensions for the terminal
from obstructions, other terminals and ventilation openings are
shown in diagram 3.2. For Ireland the minimum distances for
fl ue terminal positioning must be those detailed in I.S.813 “Do­mestic Gas Installations”.

The terminal must be exposed to the external air, allowing free
passage of air across it at all times.

Being a condensing boiler some pluming may occur from the
fl ue outlet. This should be taken into consideration when se­lecting the position for the terminal.

NOTE: If necessary it is permitted to increase the terminal pro­trusion through the outside wall to greater than the minimum di­mension of 87mm but no more than 600mm, see diagram 1.1.

Carports 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 made of plastic sheeting. If the carport
comprises of a roof and two or more walls, seek advice from
the local gas supply company before installing the boiler.

H* and J* See diagram 3.2 . These dimensions comply with
the building regulations, but they may need to be increased to
avoid wall staining and nuisance from pluming depending on
site conditions.

Plume Management Kit: Part No.A2044100 (white) or A2044000
(black) can be used to overcome many site issues.

3.3 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
minimum of 50mm clearance from any part of the terminal and
be central over the terminal.

The guard should be similar to that shown in diagram 3.3.

A suitable guard is manufactured by: -

Tower Flue Components

Morley Rd.
Tonbridge
Kent
TN9 1RA.
Size: 280mm x 280mm x 270mm.

VERTICAL FLUES

P FROM ANOTHER TERMINAL 600
Q ABOVE ROOF LEVEL 300
R FROM ADJACENT OPENING WINDOW 1000
S FROM ADJACENT WALL TO FLUE 300

Diagram 3.2

14

12325

Diagram 3.3

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4 Heating System

4.1 General

The boiler is for use only with sealed central heating systems.

The safety valve is an integral part of the boiler and it cannot
be adjusted.

The pressure gauge indicates the system pressure.

The circulation pump is integral with the boiler.

4.2 Expansion Vessel

The boiler has an integral expansion vessel with a capacity of 8
litres (1.76 gallons), with a charge pressure of 0.5bar.

NOTE: The expansion vessel volume depends on the total
water system volume and the initial system design pressure.
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”.

4.3 Flow Rate

If it is necessary to alter the fl ow rate, the system can be fi tted
with a lockable balancing valve in the main fl ow or return pipes
shown as valve “A” in diagram 4.1. The fl ow rate through the
boiler must not be allowed to fall below that given in diagram

1.2.

4.4 Bypass

The boiler is fi tted with an automatic bypass.

Diagram 4.2 shows the pump head remaining for the heating
system depending on the bypass setting and the speed setting
of the pump, see section 11 Commisioning.

Ensure that under no circumstances does the fl ow rate drop be­low the fi gure specifi ed, refer to diagram 1.2 and section 11.6.

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.

4.5 Filling the Sealed System

NOTE: The water pressure at the boiler must be at least 1.2bar

to enable fi lling the boiler to a minimum pressure.

4.6 Water Treatment

In the case of an existing system, it is ESSENTIAL that prior to
installing the new boiler the system is thoroughly fl ushed. For
optimum performance after installation of a new system, the
boiler and its associated central heating system should also
be fl ushed. Flushing should be carried out in accordance with
BS7593: 1992 using a cleanser such as Sentinel X300 or X400,
Fernox Restorer or Salamander corrosion guard cleaner.

For long-term corrosion protection, after fl ushing, a suitable in­hibitor should be used, refer to the current issue of BS 5449
and BS 7593 on the use of inhibitors in central heating systems.
Examples are Sentinel X100 Fernox Protector or Salamander
corrosion guard inhibitor.

Diagram 4.1

15

Supplied By www.heating spares.co Tel. [phone]

4 Heating System

Remaining conveyancing
capacity
Model Betacom 24
with pump’s selector
in speed position I, II, III
(automatic by-pass,
not disconnectable)

Remaining conveyancing
capacity
Model Betacom 30
with pump’s selector
in speed position I, II, III
(automatic by-pass,
not disconnectable)

Diagram 4.2

6

O

2

5,5

5

4,5

4

Pressure m. H

3,5

3

2,5

2

1,5

1

0,5

0

0 200 400 1000 1200600 800 1400

Water fl ow l/h

6

O

2

5,5

5

4,5

4

Pressure m. H

3,5

3

2,5

2

1,5

1

0,5

0

0 200 400 1000 1200600 800 1400

Water fl ow l/h

711
R00

712
R00

4.7 Draining Points

Draining taps must be provided at the lowest points of the sys­tem, which will allow the entire system to be drained.

The drain point for the appliance is provided at the position
shown in diagram 4.3.

16

Diagram 4.3

Supplied By www.heating spares.co Tel. [phone]

5 Domestic Hot Water System

General

All domestic hot water circuits, connections, fi ttings 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”.

5.1 Water Pressure

The maximum working pressure of the domestic hot water cir­cuit is 6 bar. If the cold water supply pressure exceeds this,
then a pressure-reducing valve must be fi tted in the supply to
the boiler.

6 Installation Preparation

6.1 Appliance Pack

IMPORTANT: With regards to the Health and Safety Manual

Handling requirements, two persons shall be required to lift the
appliance, refer to section 16 Manual Handling.

Please check the contents of packs as shown in diagram 6.1.

The wall hanging bracket is located at the rear of the boiler,
slide upwards to remove.

6.2 Wall Template

Take the wall template from the document pack and place in
the desired position on a fl at wall, giving due consideration to
the required boiler clearances, see section 2, and the fl ue you
are fi tting.

6.3 Flue Hole Cutting

External access fl ue installation can use a 105mm diameter
core drill.

Internal access only fl ue installation will need a 125mm diam­eter core drill.

If fl ue extension pipes are to be used then a core drill size
of 125mm is required. This will allow the extension pieces to
slope at 44mm/metre (2.5°) towards the boiler.

5.2 ‘Hard’ Water Areas

The temperatures within the heat exchanger are limited by the
boiler control system to minimise scale formation within the hot
water pipework. However, in areas where the water is ‘hard’
(i.e. more than 200mg/litre), it is recommended that the hot wa­ter setting is reduced and that a scale reducer is fi tted.

Refer to the manufacturer’s instructions or consult the local wa­ter company for additional advice.

5.3 Domestic Water Flow Rate

The water fl ow rate is restricted to a maximum 8.4 l/min for 24
and 10.0 l/min for 30, by a restrictor factory fi tted within the
boiler.

Top horizontal fl ue ­(standard and telescopic)

The standard horizontal fl ue is designed with an internal fall
of 44mm/metre (2.5°) towards the boiler for disposal of con­densate therefore the hole can be drilled horizontally. If the
standard fl ue length alone is being used then the fl ue hole of
diameter 105mm can be cut in the position marked on the wall
template.

For standard side fl ues the horizontal fl ue centre line on the
wall template should be extended to the side wall, and the ver­tical centre of the fl ue hole marked at 176mm from the back
wall.

For extended side fl ues, the fl ue hole centre should be deter­mined by extending the dashed inclined line on the template to
the side wall. This dashed line is drawn at 44mm/metre (2.5°)
rise from the boiler. Where this line reaches the side wall, a
horizontal line should be marked. The vertical centre line of the
fl ue should then be marked at 176mm from the back wall.

To allow for the fl ue passing through the wall at this angle a
125mm hole should be drilled irrespective of internal or exter­nal installation.

Remove the wall template whilst drilling the fl ue hole.

6.4 Wall Hanging Bracket Assembly

The Wall Hanging Bracket is supplied in the main boiler pack­aging at the rear of the boiler.

Reposition the wall template over the fl ue hole and mark the
position of the fi xing holes for the hanging bracket, see dia­grams on the template.

NOTE: Due to the varied site conditions we do not supply fi x­ings and advise that the installer should supply those which
are suitable.

Drill fi xing holes and insert suitable wall plugs.

17

Supplied By www.heating spares.co Tel. [phone]

Pipe pack

A - Central Heating × 2

B - Domestic Water outlet

C - Domestic Water inlet

D - Gas

Safety discharge valve pipe

(not illustrated)

6 Installation Preparation

DCBAA

Diagram 6.1

18

Supplied By www.heating spares.co Tel. [phone]

7 Gas / Water & Appliance Connection

7.2 Appliance Connection

IMPORTANT: With regards to the Manual Handling Opera-

tions, 1992 Regulations, the following lift operation exceeds
the recommended weight for a one man lift, refer to section 16
Manual Handling.

NOTE: The appliance may contain a small amount of water,
place a water container beneath the boiler connections.

Lifting the boiler into position, lean the top of the boiler slightly
to the wall and position just above the hanging bracket. Low­er the boiler slowly push back and engage onto the hanging
bracket.

Remove the protective caps.

Do the connections, interposing the sealing washers supplied
in the Loose Items pack.

Make good the fi nal connections.

1 2 43 5

A A

G

F

A - Central Heating Isolation Valve
B - Domestic Hot Water
C - Gas Service Cock
D - Domestic Cold Water
E - Washers (not shown)
F - Condensate Connection
G - Safety Discharge Valve

Numbers 1 - 5
show the sequence to be
used when tightening to
copper tails.

B D C

19

Diagram 7.1

Supplied By www.heating spares.co Tel. [phone]

8 Safety Discharge Valve & Condensate Connections

8.1 Safety Discharge Valve

The pipe from the safety discharge valve must not discharge
above an entrance, window or any type of public access area.

Take the safety discharge pipe, supplied in the pipe pack and
the union nut and seal, supplied in the loose items pack and fi t
as shown in diagram 8.1.

This must be extended, using not less than 15mm o.d. pipe,
to discharge, in a visible position, outside the building, facing
downwards, preferably over a drain.

The pipe must have a continuous fall and be routed to a posi­tion so that any discharge of water, possibly boiling, or steam
cannot create any danger to persons, damage to property or
external electrical components and wiring.

To ease future servicing it is advisable to use a compression
type fi tting to extend the safety discharge valve tube.

8.2 Condensate Drain Connection

The condensate drain connection is at the rear of the boiler,
see diagram 7.1. A fl exible condensate outlet pipe is supplied
fi tted to the boiler and should be used to fi t onto the drain con­nection, to discharge condensate to a drain. The drain pipe
22mm to 25mm OD. non corrosive plastic pipe should have a
fall of at least 2.5° away from the boiler.

Condensate should, if possible be discharged into the house­hold internal drainage system. If this is not practicable, dis­charge can be allowed into the external household drains or a
purpose designed soak away, refer to diagram 8.2.

It is recommended that any external condensate drain pipe is
insulated and also preferably of 32mm diameter, to prevent
freezing in adverse weather conditions.

It is not necessary to provide air breaks or extra traps in the
discharge pipe as there is already a trap inside the boiler.

Refer to BS5546 or BS6798 for advice on disposal of boiler
condensate.

Diagram 8.1

20

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8 Safety Discharge Valve & Condensate Connections

INTERNAL SOIL
AND VENT STACK

Internal Soil and Vent Pipe

EXTERNAL LENGTH
OF PIPE 3M MAX.

*

BOILER

MIN. DIA. 21mm
NO RESTRICTION
ON LENGTH

BOILER

MIN. DIA. 21mm

EXTERNAL SOIL
AND VENT STACK

EXTERNAL
MAX. 3M

MIN. DIA. 21mm
NO RESTRICTION
ON LENGTH

BOILER

External Soil and Vent Pipe or Rainwater Pipe

SINK
(CONSTITUTES
AIR BREAK)

MIN. DIA. 21mm
NO RESTRICTION
ON LENGTH

BOILER

13000

OPEN END OF PIPE
DIRECT INTO GULLEY
BELOW GROUND BUT
ABOVE WATER LEVEL

*NOTE: FOR EXTENDED
PIPE RUNS 32mm DIA.
PIPE SHOULD BE USED.

External Termination to a Gulley or Hopper

MIN. DIA. 21mm
NO RESTRICTION
ON LENGTH

BOILER

OPEN END OF PIPE DIRECT INTO
GULLEY BELOW GROUND LEVEL
BUT ABOVE WATER LEVEL.

SINK

Internal Termination Downstream of
Sink Waste

Internal Termination into Combined Sink Waste

EXTERNAL LENGTH OF PIPE
3M MAX.

Ø22mm MIN.
TERMINATION FROM APPLIANCE.

GROUND

500mm MIN.

25mm MIN.
Ø100mm
PLASTIC TUBE

BOTTOM OF
TUBE SEALED

LIMESTONE CHIPPINGS

HOLE DEPTH
400mm MIN.

SEAL

2 ROWS OF 3 x 12mm HOLES AT
25mm CENTRES 50mm FROM
BOTTOM OF TUBE. HOLES TO
FACE AWAY FROM HOUSE.

(either/or)

300mm
MIN.

External Termination into Soakaway

NOTE: PIPEWORK SHOULD ALWAYS FALL AWAY FROM BOILER BY AT LEAST 2.5
44mm FOR EVERY 1M.

21

o

Diagram 8.2

Supplied By www.heating spares.co Tel. [phone]

9 Flue Preparation and Installation

9.1 Top Horizontal Rear fl ue - Telescopic
Part No. A2043600.

Refer to diagram 9.1 for kit contents.

9.2 Flue Length

If a wall thickness of 204mm min. to 409mm max. the Top hori­zontal rear fl ue - telescopic can be used without extensions.

If the wall thickness is greater than 409mm then using exten­sions a maximum horizontal fl ue length of 4 metres (24kW) &
3 metres (30kW) plus the Top horizontal rear fl ue - telescopic
can be achieved. However, for every 90° or 45° elbows used
the fl ue length MUST be reduced by 1 metre.

When extension pipes are used the fl ue system must be de­signed to have a continuous fall to the boiler of at least 44mm/
metre (2.5°) to allow condensate to run back into the boiler and
out via the drain.

9.3 Preparation

Using these screws inserted into the same holes on the boiler,
tighten and secure the fl ue hood top, see diagram 9.3.

Temporarily fi t the fl ue elbow, measure the distance from the
outside wall to fl ue elbow. If the measurement ‘Y’ exceeds
525mm, see diagram 9.3, then the appropriate length of exten­sion pipe is required. If the dimension is less than 320mm DO
NOT cut the fl ue, it can project beyond the outside wall face,
see diagram 9.4. If this is not desirable then a Top horizontal
rear fl ue - standard MUST be used and cut to length.

12925

Diagram 9.1

9.4 Flue Fitting

Set the fl ue to the required length ‘Y’, ensure the air duct seams
line up.

Remove the fl ue elbow.

Mark the securing hole position in the air duct. Drill a 3mm
diameter hole at this position, take care not to pierce the inner
fl ue duct. Secure with screw provided and tape the joint, see
diagram 9.5.

Fit the sealing collar onto the locating ring on the fl ue terminal,
see diagram 9.6.

Push the fl ue assembly into the wall, externally or internally,
until the end of the assembly protrudes a short way from the
inside face of the wall. This will enable the internal trim ring (if
required) to be positioned and allow the fl ue assembly to be
drawn back up to the fl ue elbow.

Secure the fl ue elbow in position on top of the boiler with four
torque headed screws supplied.

Draw the fl ue assembly from wall and engage the fl ue duct into
the elbow and butt fi t between the air duct and fl ue elbow.

Ensure the correct alignment of the fl ue.

Fit the securing collar in position, mark through two of the pre
drilled holes in the securing collar. Remove securing collar
and drill two 3mm diameter holes one in the elbow and one in
the air duct, take care not to pierce the inner fl ue duct. Fit the
securing collar and secure with screws provided, see diagram

9.7.

Slide the internal trim ring back against the wall, securing in
place with a small amount of sealant if required.

12806

Diagram 9.3

22

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9 Flue Preparation and Installation

Diagram 9.4

12979

12929

13018

Diagram 9.7

9.5 Top Horizontal Rear fl ue - Standard
Part No. A2043400.

Refer to diagram 9.8 for kit contents.

Diagram 9.5

12977

9.6 Flue Length

If a wall thickness of 75 min. to 507 max. the Top horizontal rear
fl ue - standard can be used without extensions.

If the wall thickness is greater than 507 then using extensions
a maximum horizontal fl ue length of 4 metres (24kW) & 3 me­tres (30kW) plus the top horizontal rear fl ue - standard can be
achieved. However, for every 90° or 45° elbows used the fl ue
length MUST be reduced by 1 metre.

When extension pipes are used the fl ue system must be de­signed to have a continuous fall to the boiler of at least 44mm/
metre (2.5°) to allow condensate to run back into the boiler and
out via the drain.

Temporarily fi t the fl ue elbow, measure the distance from the
outside wall to fl ue elbow. If the measurement ‘Y’ exceeds
652mm, then the appropriate length of extension pipe is re­quired. The minimum dimension is 187 to suit a 75 min. wall
thickness, see diagram 9.3.

9.7 Flue Fitting

Remove the fl ue elbow.

Separate the fl ue duct from the terminal by twisting to release
the terminal catch, then pull out of the retaining seal, refer to
diagram 9.9.

The fl ue duct cutting length (L + 11mm.) is shown in diagram

9.9.

The air duct should be cut at the opposite end to the terminal

The plastic fl ue duct MUST be cut at the opposite end to the
terminal catch.

The plastic fl ue duct extensions MUST be cut at the opposite
end to the seal.

Diagram 9.6

23

Supplied By www.heating spares.co Tel. [phone]

9 Flue Preparation and Installation

The cut ducts must be de-burred and all fi lings and debris re­moved.

Insert the fl ue duct into the air duct terminal assembly, remem­bering to engage the catch within the terminal.

NOTE: If you require to lubricate the seals to ease installation,
do not use mineral oils or grease, silicon grease or water is
recommended.

Fit the sealing collar onto the locating ring on the fl ue terminal,
see diagram 9.6.

Push the fl ue assembly into the wall, externally or internally, ini­tially until the end of the assembly protrudes a short way from
the inside face of the wall. This will enable the internal trim ring
(if required) to be positioned and allow the fl ue assembly to be
drawn back into the fl ue elbow.

Secure the fl ue elbow in position on top of the boiler with four
torque headed screws supplied.

Draw the fl ue assembly from wall and engage the fl ue duct into
the elbow and butt fi t between the air duct and fl ue elbow.

Ensuring the correct alignment of the terminal.

Fit the securing collar into position, mark through two of the
pre drilled holes in the securing collar. Remove securing collar
and drill two 3mm diameter holes one in the elbow and one in
the air duct, take care not to pierce the inner fl ue duct. Fit the
securing collar and secure with screws provided, see diagram

9.10.

Slide the internal trim ring back against the wall, securing in
place with a small amount of sealant if required.

NOTE: If the air and fl ue ducts have been correctly cut to the
instructions given, the sealing collar should fi t fl ush with the
outside wall, check this.

13mm

L

AIR DUCT

L

TERMINAL
CATCH

12967

Diagram 9.8

12847

FLUE DUCT

L + 11mm

Diagram 9.9

13019

24

Diagram 9.10

Supplied By www.heating spares.co Tel. [phone]

9 Flue Preparation and Installation

9.8 Top Horizontal Side fl ue - Telescopic
Part No. A2043600.

Refer to diagram 9.1 for kit contents.

9.9 Flue Length

The maximum permissable horizontal fl ue length is 4 metres
(24kW) & 3 metres (30kW) plus the Top horizontal side fl ue

- telescopic. This can be achieved by the use of extensions,
however, for every 90° or 45° elbows used the fl ue length
MUST be reduced by 1 metre.

When extension pipes are used the fl ue system must be de­signed to have a continuous fall to the boiler of at least 44mm/
metre (2.5°) to allow condensate to run back into the boiler and
out via the drain.

50 MIN.

9.10 Preparation

Temporarily fi t the fl ue elbow, measure the distance from the
outside wall to fl ue elbow. If the measurement ‘Y’ exceeds
525mm, see diagram 9.11 then the appropriate length of exten­sion pipe is required. If the dimension is less than 320mm DO
NOT cut the fl ue, it can project beyond the outside wall face,
see diagrams 9.4. If this is not desirable then a Top horizontal
side fl ue - standard MUST be used and cut to length.

9.11 Flue Fitting

Set the fl ue to the required length ‘Y’, ensure the air duct seams
line up.

Remove the fl ue elbow.

Mark the securing hole position in the air duct. Drill a 3mm
diameter hole at this position, take care not to pierce the inner
fl ue duct. Secure with screw provided and tape the joint, see
diagram 9.5.

Fit the sealing collar onto the locating ring on the fl ue terminal,
see diagram 9.6.

Push the fl ue assembly into the wall, externally or internally,
until the end of the assembly protrudes a short way from the
inside face of the wall. This will enable the internal trim ring (if
required) to be positioned and allow the fl ue assembly to be
drawn back up to the fl ue elbow.

Secure the fl ue elbow in position on top of the boiler with four
torque headed screws supplied.

Draw the fl ue assembly from wall and engage the fl ue duct into
the elbow and butt fi t between the air duct and fl ue elbow.

Ensure the correct alignment of the fl ue.

Fit the securing collar in position, mark through two of the pre
drilled holes in the securing collar. Remove securing collar
and drill two 3mm diameter holes one in the elbow and one in
the air duct, take care not to pierce the inner fl ue duct. Fit the
securing collar and secure with screws provided, see diagram

9.12.

Slide the internal trim ring back against the wall, securing in
place with a small amount of sealant if required.

Left Hand illustrated

Diagram 9.11

13020

Diagram 9.12

25

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9 Flue Preparation and Installation

9.12 Top Horizontal Side fl ue - Standard
Part No. A2043400.

Refer to diagram 9.8 for kit contents.

9.13 Flue Length

Remove the top fl ue outlet cover secured with four screws, see
diagram 9.2.

Temporarily fi t the fl ue elbow, measure the distance from the
outside wall to fl ue elbow. If the measurement ‘Y’ exceeds
652mm, then the appropriate length of extension pipe is re­quired.

9.14 Flue Fitting

Remove the fl ue elbow.

Separate the fl ue duct from the terminal by twisting to release
the terminal catch, then pull out of the retaining seal, refer to
diagram 9.9.

The fl ue duct cutting length (L + 11mm.) is shown in diagram

9.9.

The air duct should be cut at the opposite end to the terminal

The plastic fl ue duct MUST be cut at the opposite end to the
terminal catch.

The plastic fl ue duct extensions MUST be cut at the opposite
end to seal.

The cut ducts must be de-burred and all fi lings and debris re­moved.

Insert the fl ue duct into the air duct terminal assembly, remem­bering to engage the catch within the terminal.

NOTE: If you require to lubricate the seals to ease installation,
do not use mineral oils or grease, silicon grease or water is
recommended.

Fit the sealing collar behind the locating lugs on the fl ue termi­nal, see diagram 9.6.

Push the fl ue assembly into the wall, externally or internally, ini­tially until the end of the assembly protrudes a short way from
the inside face of the wall. This will enable the internal trim ring
(if required) to be positioned and allow the fl ue assembly to be
drawn back into the fl ue elbow.

Secure the fl ue elbow in position on top of the boiler with four
torque headed screws supplied.

Draw the fl ue assembly from wall and engage the fl ue duct into
the elbow and butt fi t between the air duct and fl ue elbow.

Ensuring the correct alignment of the terminal.

Fit the securing collar into position, mark through two of the
pre drilled holes in the securing collar. Remove securing collar
and drill two 3mm diameter holes one in the elbow and one in
the air duct, take care not to pierce the inner fl ue duct. Fit the
securing collar and secure with screws provided, see diagram

9.13.

Slide the internal trim ring back against the wall, securing in
place with a small amount of sealant if required.

NOTE: If the air and fl ue ducts have been correctly cut to the
instructions the sealing collar should fi t fl ush with the outside
wall, check this.

13022

Diagram 9.13

26

Supplied By www.heating spares.co Tel. [phone]

9 Flue Preparation and Installation

9.15 Vertical fl ue

The vertical fl ue system is available as an option where the
boiler position does not permit the use of the top horizontal or
rear fl ue system.

The system is made up of accessories. The accessories include
terminal assembly, bends 45° and 90°, fl ue extensions, fi xing
bracket and appropriate weather collar, see diagram 9.17.

The maximum permitted straight fl ue length is 8 metres plus
the terminal. for each 90° or 2x45° bends fi tted, the maximum
length must be reduced by 1 metre, see diagram 9.22.

NOTE: 2x45º bends can replace 1x90° bend if necessary.
When using 90º bends any horizontal extension pipe should
be inclined by a minimum of 44mm/metre (2.5°) towards the
boiler to facilitate condense removal, see (a) in diagram 9.22.

Alternatively use 45º bends to avoid horizontal runs, see (b) in
diagram 9.22.

The terminal should be positioned at least 600mm from any
opening into the building, refer to diagram 3.2.

Measure the distance of fl ue length required for the installa­tion.

The fl ue must be designed with a continuous fall towards the
boiler.

Remove the top fl ue outlet cover secured with four screws, see
diagram 9.2.

Refer to diagram 9.18. Secure the fl ue adapter in position on
top of the boiler with four torx headed screws supplied, mak­ing sure the nib fi ts into the locating slot in the boiler casing to
ensure correct orientation.

The rubber ‘O’ rings of each section should be lubricated prior
to assembly.

NOTE: Do not use mineral oils or grease, silicon grease or
water is recommended.

Secure the fi rst extension pipe to the fl ue adapter with the se­curing collar supplied by positioning the collar centrally over
the joint, then tighten the two screws on the securing collar,
see diagram 9.19.

Fit more extension pipes as required using the collar and
screws supplied with each extension pipe. To fi t position the
collar centrally over the joint, tighten the two screws on the
securing collar. Using the holes provided in the securing collar
drill and insert the two self tapping srews supplied, see dia­gram 9.20.

The rubber ‘O’ rings of each section should be lubricated prior
to assembly.

NOTE: Do not use mineral oils or grease, silicon grease or
water is recommended.

When building the fl ue up it is recommended that it is sup­ported every 2 metres and at every bend by a fi xing bracket.

Project the rise of the fl ue pipe to roof level and cut a 150mm
hole in the roof.

12969

27

Diagram 9.17

Supplied By www.heating spares.co Tel. [phone]

9 Flue Preparation and Installation

Flue Terminal Installation

(a) Pitched Roof

Fit the required pitched roof weather collar over the 150mm
hole in the roof. Make good the tiling or slating around the col­lar incorporating the fl ashing of the weather collar. Position the
angle cap over the weather collar in the correct orientation to
attain the correct angle for your roof.

(b) Flat Roof

Fit the aluminium weather collar over the 150mm hole in the
roof ensuring a weather tight seal.

From above carefully place the fl ue terminal through the weath­er collar.

Completion of Installation

With the fl ue terminal positioned in the roof the length of the
fi nal pipe can be determined. If a telescopic length cannot
be used, then a standard fl ue length can be cut to make the
correct length. Cut the fl ue to the desired length measuring
from the ‘O’ ring end and discard the plain end of the tube. The
cuts must be square and made free of burrs to allow correct
assembly. (NOTE: The fl ue pipe is 10mm longer than the air
pipe), see diagram 9.21. Carefully push the terminal assembly
upwards to allow room for fi tting the fi nal fl ue piece. Fit a fi xing
bracket to the terminal assembly. Pull the terminal assembly
down and join to the fl ue system. Ensure that the terminal is
making a weather tight seal on the weather collar. Secure the
fi xing bracket fi tted to the terminal to the roofi ng struts or a
purpose made batton.

Diagram 9.18

28

Diagram 9.19

12982

Diagram 9.20

Supplied By www.heating spares.co Tel. [phone]

9 Flue Preparation and Installation

12983

Diagram 9.21

5

G

D

When the length of the fl ue system is less than 2
metres, it is necessary to install the fl ue restrictor
“D”. The length of the system is specifi ed for each
fl ue confi guration.

Remove the gasket “G”, install the restrictor “D”
and install the gasket “G”.

29

34

Diagram 9.22

Supplied By www.heating spares.co Tel. [phone]

9 Flue Preparation and Installation

12970

9.16 Twin fl ue

The twin fl ue system is available as an option when the top
horizontal, rear or vertical fl ue system is not appropriate.

The system can provide an independent horizontal air inlet and
fl ue outlet, horizontal air inlet and vertical fl ue outlet or vertical
air inlet and fl ue outlet via a concentric terminal.

NOTE: The air and fl ue outlets do not have to be equal lengths.
2x45° bends can replace 1x90° bend if necessary.

The maximum permitted straight pipe length is 10 metres plus
terminal assemblies, for each 90° or 45° x 2 bends fi tted, the
maximum length must be reduced by 1 metre.

NOTE: When using 90° bends any horizontal run should be
inclined by a minimum of 44mm/metre (2.5°) towards the boiler
to facilitate condense removal.

Alternatively use 45° bends to avoid horizontal runs in the fl ue
pipe.

Terminal Position

The clearances for a fl ue outlet are given in the "Flue Location
and Ventilation" section.

In addition the horizontal air inlet must not be closer than 300
mm from a fl ue outlet on the same wall or 1200mm from an op­posing fl ue outlet.

Installation Details

The parts available for a twin fl ue system installation are shown
in diagram 9.23.

Boiler Connection

Remove the top fl ue outlet cover secured with four screws, see
diagram 9.2

Push the twin fl ue adaptor onto the outlet of the boiler with the
air inlet to the left hand side. Secure the adaptor to the top
panel with the screws provided. Care should be taken when
inserting the screw through the hole in adaptor top.

To facilitate engagement, it is recommended that the rubber
‘O’ rings are lubricated with silicone grease or water prior to
assembly.

See diagram 9.24 new adaptor in position.

Air and Flue Pipe Installation

The air and fl ue pipes can now be built up from the boiler.

The fl ue must be designed with a continuous fall towards the
boiler. If using the horizontal fl ue pipe or 90° bends the pipe
must be inclined at 44mm/metre (2.5°) minimum, see diagram

9.25.

Alternatively if space allows, use 45° bends in place of 90º
bends.

The rubber ‘O’ rings of each section should be lubricated prior
to assembly with silicone grease.

When building the fl ue up it is recommended that it is supported
every 2 metres and at every bend by a fi xing bracket.

Diagram 9.23

30

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9 Flue Preparation and Installation

Horizontal Terminal Installation

With due consideration to terminal clearances mentioned in
Section 3.2 drill the one or two holes as required with a 90mm
core drill.

Push the horizontal terminal through the wall allowing approx.
100mm to protrude outside.

Push a grey rubber wall seal onto either side of the wall ensur­ing that both wall seals are pushed up to the wall surface, see
examples (b) and (c) diagram 9.25.

Vertical Terminal Installation

With due consideration to terminal clearances mentioned in
Section 3.2, project the rise of the fl ue pipe to roof level and cut
150mm hole in the roof.

(a) Pitched Roof

Fit the required pitched roof weather collar over the 150mm
hole in the roof. Make good the tiling or slating around the col­lar incorporating the fl ashing of the weather collar. Position the
angle cap over the weather collar in the correct orientation to
attain the correct angle for your roof. One way round gives a
pitch of 25°-38° and the other gives 37°- 50°.

(b) Flat Roof

Diagram 9.24

Fit the aluminium weather collar over the 150mm hole in the
roof ensuring a weather tight seal.

Horizontal Pipes-Completion of Installation

Having built the pipe(s) from the boiler to the terminal(s), the
length of the fi nal pipe piece can be determined. Cut pipes at
the opposite end to the ‘O’ ring seal making square and free
from burrs. Push the horizontal terminal through the wall to en­gage the fi nal pipe piece and pull back ensuring the grey wall
seals are fully pulled up to the outside and inside wall faces.

Vertical Pipes-Completion of Installation

Refer to diagram 9.25.

For installation of (a), attach the twin pipe to concentric fl ue
adaptor, part number A2011600, to the base of vertical terminal
assembly. For installation of (b), attach the single pipe to con­centric adaptor, part number A2011500, to the base of vertical
terminal assembly.

With the vertical terminal assembly positioned in the roof, the
length of the fi nal pipe can be determined. Cut the fl ue to the
desired length measuring from the ‘O’ ring seal end and discard
the plain end of the tube. The cut end should be square and
free from burrs. Carefully push the terminal assembly upwards
to allow room for fi tting the fi nal fl ue piece(s). Fit a 100mm fi x­ing bracket to the terminal assembly Part No2000460486. Pull
the terminal assembly down and join to the fl ue system. Ensure
that the terminal is making a weather tight seal on the weather
collar. Secure the fi xing bracket fi tted to the terminal to the roof­ing struts or a purpose made batton.

31

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9 Flue Preparation and Installation

When the length of the fl ue sys-

G

D

tem is less than 4 metres, it is
necessary to install the fl ue re­strictor “D”. The length of the
system is specifi ed for each fl ue
confi guration.

Remove the gasket “G”, install
the restrictor “D” and install the
gasket “G”.

32

Diagram 9.25

Supplied By www.heating spares.co Tel. [phone]

9 Flue Preparation and Installation

IMPORTANT: The flue outlet must
not be positioned within 300mm
from an opening, air brick or
opening windows.

FLUE
OUTLET

FLUE
PRODUCTS

PLUME
MANAGEMENT
KIT

AIR BRICK

9.17 Plume Management Kit

The Plume Management Kit: Part No. A2044100 (white) or
A2044000 (black) can be used to overcome many site issues.

The Plume Management Kit will fi t to the Top Horizontal Tel­escopic, Rear Horizontal Telescopic and Standard Horizontal
Flue. This enables the fl ue products to exhaust further away
from the boiler, thereby reducing the impact of pluming. The
fl ue air inlet can be sited closer to doors, opening windows and
air bricks, see diagram 9.26.

The maximum length of the Plume Management Kit must NOT
exceed 6m with a horizontal concentric fl ue length of 2m max.

For each 90° bend or 2 x 45° bends the maximum length of the
Plume Management Kit must be reduced by 1m.

For more information contact Glow-worm, refer to page 2.

The Plume Management Kit is supplied with installation instruc­tions.

OPENING
WINDOW
OR DOOR

25mm. MIN.

50mm.
MIN.

AIR INLET

Diagram 9.26

33

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10 Electrical Connection

WARNING: This appliance must be earthed.

This appliance must be wired in accordance with these instruc­tions. Any fault arising from incorrect wiring cannot be put right
under the terms of the Glow-worm guarantee.

All system components must be of an approved type.

Electrical components have been tested to meet the equivalent
requirements of the BEAB.

Do not interrupt the mains supply with a time switch or pro­grammer.

Connection of the whole electrical system and any heating sys­tem controls to the electrical supply must be through a com­mon isolator.

Isolation should preferably be by a double pole switched fused
spur box having a minimum contact separation of 3mm on
each pole. The fused spur box should be readily accessible
and preferably adjacent to the boiler. It should be identifi ed as
to its use.

A fused three pin plug and shuttered socket outlet may be used
instead of a fused spur box provided that:

a) They are not used in a room containing a fi xed bath or show­er.

b) Both the plug and socket comply with the current issue of
BS1363.

10.2 Mains Voltage System Controls

WARNING: The Betacom is designed exclusively for use with
potential free system controls. Under no circumstances must
any mains voltage be applied to the white controls con­nection lead.

10.3 Electrical Connections - Testing

Carry out preliminary electrical system checks as below:

1. Test insulation resistance to earth of mains cables.

2. Test the earth continuity and short circuit of cables.

3. Test the polarity of the mains.

10.1 System Controls

WARNING: UNDER NO CIRCUMSTANCES MUST ANY MAINS

VOLTAGE BE APPLIED TO THE CONNECTION LEAD.

Connect the mains supply and system heating controls e.g.
room thermostat as diagram 10.1. External controls should be
fi tted in accordance with the rules in force.

IMPORTANT NOTE

ALL electrical connections to the boiler

must be permanently fi xed to a wall or a

sturdy support feature in a tidy manner.

34

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10 Electrical Connection

FUSED MAINS

SPUR OR

FUSED 3 PIN

PLUG

BOILER

BLACK MAINS LEAD WHITE EXTERNAL CONTROL LEAD

Internal time clock (factory fitted)

External potential-free room thermostat

FUSED MAINS

SPUR OR

FUSED 3 PIN

PLUG

BOILER

BLACK MAINS LEAD WHITE EXTERNAL CONTROL LEAD

Internal time clock (factory fitted) disconnected

External potential-free room thermostat

External potential-free programmer

PROGRAMMER

POTENTIAL

FREE ROOM

THERMOSTAT

ROOM

THERMOSTAT

1) INTERNAL TIME CLOCK WITH EXTERNAL
ROOM THERMOSTAT

If a room thermostat is required it must be connected to
the external controls lead as shown, using a suitable elec­trical connection.

617R01

2) CONNECTION WITH EXTERNAL PRO­GRAMMER

Any eventual external programmer must be connected in
series with the room thermostat.

IMPORTANT: the boiler time clock must be put on po­sition “I” (see Diagram 10.2).

617A

FUSED MAINS

SPUR OR

FUSED 3 PIN

PLUG

BOILER

BLACK MAINS LEAD WHITE EXTERNAL CONTROL LEAD

Internal time clock (factory fitted) disconnected

External potential-free chrono-thermostat

PROGRAMMABLE

ROOM THERMOSTAT

REMARK: In case of installation of an
external programmer or chronothermo­stat (see Diagram 10.1) the internal time
clock (factory fi tted) must be put on
position “I” (always ON)

3) CONNECTION WITH EXTERNAL
PROGRAMMABLE ROOM THERMOSTAT

As an alternative solution it is possible to connect a
single external programmable room thermostat which
makes the double function of a room thermostat and a
programmer (see fi gure 3)

IMPORTANT: the boiler time clock must be put on po­sition “I” (see Diagram 10.2).

617B_R01

Diagram 10.1

35

Diagram 10.2

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11 Commissioning

11.1 Filling the System

Refer to diagram 11.1

1. Ensure that the fi lling loop is connected to the fi lling con­nections on the heating system.

2. Open the Central Heating Flow and Return cocks marked
‘1’ and ‘2’ - knob in line with the axis of the cock (shown
open in diagram).

3. The gauge ‘4’ shows the system pressure.

4. Open the fi lling loop to fi ll the heating system to a pressure
of 1.0bar, then close it.

5. Vent all air from the system - repeat step 4 as neccessary
until the system is full and all the air has been removed.

6. After fi lling is complete set the Central Heating temperature
and the Domestic Hot Water temperature to the desired
level. Refer to “Instructions for Use” manual for details.

7. Disconnect the fi lling loop in compliance with the water
regulations.

11.2 Filling Domestic Water Circuit

1. Fully open any valves in the domestic water supply to the
boiler.

2. Open the domestic water isolation valve marked ‘3’ in Dia­gram 11.1 - knob in line with the axis of the cock (shown
open in diagram).

3. Open all hot water taps in turn and close them when water
fl ows. Check for water soundness of the complete domes­tic water system.

11.3 Re-pressurising System

1. Ensure that the fi lling loop is connected to the fi lling con­nections on the heating system.

2. The gauge ‘4’ shows the system pressure. Open the fi lling
loop to fi ll the heating system to a pressure of 1.0bar, then
close it.

3. Vent all air from the system - repeat step 2 as neccessary
until the system is full and all the air has been removed.

4. Disconnect the fi lling loop in compliance with the water
regulations.

11.4 Water fl ow rate

The water fl ow rate is restricted by a restrictor factory fi tted to
the boiler.

1 2 3

36

4

Diagram 11.1

Supplied By www.heating spares.co Tel. [phone]

11 Commissioning

11.5 Initial Lighting

The lighting procedure of the boiler is fully automated.

Check that all external controls are calling for heat.

The appliance will enter a self checking routine then the fan
should start and the ignition will commence.

If the burner fails to light the boiler will block. Initially this may
be due to air in the gas supply line. The boiler will automatically
have some attempts at ignition.

If the burner fails to ignite the indicator

Turn the left knob on
operating position to repeat the ignition sequence.

Once the system has been purged of air set the hot water to
the desired temperature by using the Hot Water knob

Open a hot water tap, the diverter valve will move to hot water
supply.

Check that hot water is available and then close the hot water
tap.

Set the Central heating water temperature to the desired tem­perature by turning the Central Heating knob on the scale

The appliance will then continue to fi re in central heating un­til the user controls are satisfi ed or there is another demand
made for hot water.

position and then turn it on previous

will turn on.

.

11.6 Testing

Should any doubt exist about the gas rate, check it using the
gas meter test dial and stop watch at least 10 minutes after
the burner has lit, making sure that all other gas burning appli­ances and pilot lights are off.

It should be noted that this appliance will modulate the heat in­put according to demand. This may affect the gas rates meas­ured if the appliance reaches its operating temperature during
the measurement.

The approximate gas rates:

Betacom 24: 2.7m³/h

Betacom 30: 3.1m³/h

The gas valve is factory set for natural gas (G20) and should
need no adjustment.

Re-setting of the gas valve requires a combustion analyser and
any adjustment should only be carried out by a competent per­son.

11.7 Testing - Heating System

Check that all external controls are calling for heat. The boiler
will fi re automatically. Fully open all radiator valves, fl ow con­trol valve, if fi tted, see diagram 4.1.

Balance the radiators as required and if fi tted adjust valve to
give the required system differential. Turn off all radiators that
can be shut off by the user and check to see if less than the
maximum differential allowed of 20°C can be achieved across
fl ow and return.

The pump’s speed can be adjusted depending on the require­ments of the central heating system, see diagram 4.2.

The appliances have an inbuilt automatic bypass valve.

Allow the system to reach maximum temperature then switch
off the boiler by isolating from the electrical supply.

Drain the entire system rapidly whilst hot, using the drain tap
at the lowest part of the system. Fill and vent the system as
described previously in section 11.1.

Lock or remove the handle from control valve, if fi tted.

.

11.8 Completion

Adjust the boiler temperature control and any system controls
to their required settings. In addition it is necessary to complete
the “Benchmark” logbook.

For IE, it is necessary to complete a “Declaration of Conformity”
to indicate compliance to I.S.813. An example of this is given in
the current edition of I.S.813.

Testing Flue Gases: If any doubt exists that the fl ue products
are not exhausting correctly, investigate by use of a gas ana­lyser (FGA).

37

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11 Commissioning

11.9 Heating power adjustment

The maximum heating output must be set in accordance with
the system requirements (stated in the project). Once you
know the power suitable for the heating system, refer to the
“BURNER PRESSURES” tables in Section 1 (Technical Infor­mation) and fi nd the burner pressure for the boiler model and
for the type of gas used.

The regulation will be performed by the boiler’s controls, fol­lowing a special procedure that avoids accidental activations
by the User.

Refer to Diagram 11.2.

— Loosen (2-3 turns) the screw of pressure tapping point for

gas outlet [1] of the gas valve and insert the manometer
sensor. Unthread from the “Vent” [3] the silicon tube com­ing from the sealed chamber;

— supply the boiler and turn the Central Heating knob

Summer position

— ensure that there are NOT domestic hot water requests

(no open taps); if the room thermostat is installed, make
sure it is calling for heat (e.g. raise the requested room
temperature manually);

— turn the Hot Water knob

mately fi ve seconds) that both the green
indicators fl ash to short “pulses”. When that happens,
within 15 seconds turn the Central Heating
the MAXIMUM value of the scale of the heating
clockwise). The burner ignites to the maximum output not
modulated (the yellow indicator

— read on the manometer the value of the gas pressure to

the burner and turn the Central Heating
heating system temperature scale
the manometer, the burner pressure corresponding to the
power needed:

— do NOT move the Central Heating

seconds, until the green indicator
stays on. During this time, check that the pressure dis­played on the manometer remains stabilized on the correct
value;

— turn the Hot Water knob

burner will turn off for a moment. Wait (about 5 seconds)
that both the green
about 5 seconds (this is the confi rmation that the burner
pressure for heating is stored), then the red indicator
turns off;

— reinsert the tube in the “Vent” [3] of the gas valve. ATTEN-

TION:after this operation, the value measured by the ma­nometer could decrease due to pressure compensation.
This fact is normal and does not require any change of the
regulation;

— unthread the manometer sensor and screw the pressure

tapping point screw for gas outlet [1]; verify that there is no
gas leak;

— to switch off the burner, turn the Central Heating knob

to the position

The MAX power for the heating system is adjusted now.

The whole procedure should be completed within 15 minutes
from the start. If you exceed this time, or in case of mistakes,
the new pressure will not be stored and it will be necessary to
repeat the procedure from the beginning, by turning the Cen­tral Heating knob
scale from I to

.

;

on position and wait (approxi-

and red

turns on);

knob along the

, until you read, on

knob for about 30

stops fl ashing and

on the scale from I to ; the

and red indicators stay on for

.

on and the Hot Water knob on the

.to

knob on

(fully

3

1

4

C

2

892_R00

B

A

1 = Pressure tapping point for gas outlet

2 = Pressure tapping point for gas inlet

3 = Vent

Diagram 11.2

38

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11 Commissioning

11.10 Instruct the User

Instruct and demonstrate the lighting procedure and advise the
user on the safe and effi cient operation of the boiler.

Instruct on and demonstrate the operation of any heating sys­tem controls.

Advise the user on the use and maintenance of any scale re­ducer and pass on any relevant instructional documents.

Advise that to ensure the continued effi cient 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 installation conditions and usage, but in general, once
a year should be enough.

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 in the UK.

The user shall not interfere with or adjust sealed components.

It is the Law that any servicing is carried out by a competent
person.

Advise the user that, like all condensing boilers this appliance
will produce a plume of condensation from the fl ue terminal in
cool weather. This is due to the high effi ciency and hence low
fl ue gas temperature of the boiler.

Advise the user of the precautions necessary to prevent dam­age to the system, boiler and the building, in the event of the
heating system being out of use during frost or freezing condi­tions.

Advise the user that the permanent mains electrical supply
SHOULD NOT be switched off, as the built in frost protection
and pump/valve saver program would not be operable.

Reminder, leave these instructions and the ‘Benchmark’ log­book with the user.

39

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12 Servicing

Important Notes

To ensure the continued effi cient 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 is carried out by a competent

person.

When replacing a part on this appliance, use only spare parts
that you can be assured conform to the safety and performance
specifi cation that we require. Do not use reconditioned or copy
parts that have not been clearly authorised by Glow-worm.

Before commencing with a service or replacement of parts the
boiler should be isolated from the electrical supply and the gas
supply should be turned off at the gas service cock, see dia­gram 12.1.

Testing Flue Gases: If any doubt exists that the fl ue products
are not exhausting correctly, investigate by use of a gas ana­lyser (FGA).

Measurement of the products of combustion can be achieved
by connecting a probe to the combustion analyser test point on
the fl ue elbow, refer Combustion Check.

IMPORTANT NOTE: Products of combustion will be dis­charged when the cap is removed. It is important to replace the
cap immediately.

GAS COCK

Diagram 12.1

12.1 Combustion Check

A combustion check should not be necessary unless a gas car­rying component has been replaced or the combustion setting
is suspect.

Connect a CO2 combustion analyser to the test point, see dia­gram 12.2.

Turn on the gas service cock, see diagram 12.1.

Turn on the electrical supply.

A competent person only should carry out any adjustment
to the gas valve.

• supply the boiler and turn the Central Heating knob
Summer position

• ensure that room thermostat contact is closed (activated)
or open an hot water tap (the heat produced by the boiler
will be drained consequently);

• turn the Hot Water knob
(about 5 seconds) that green lamp
intervals. When this occurs, turn the Hot Water knob
the scale from I to
output not modulated;

• perform the combustion check;

• switch off the burner, by turning the Central Heating knob

to the position . The green lamp fl ashes with long

intervals.

Remark: the burner will switch off automatically when reach-

ing the maximum temperature, and in any case after 15
minutes.

;

to the position and wait

fl ashes with short

. The burner ignites at the maximum

to

on

TEST POINT

Diagram 12.2

40

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12.2 General

12 Servicing

Removal of the front panel is required for all routine servicing.
Refer to diagram 12.3.

Unless stated otherwise any part removed during servicing
should be replaced in the reverse order to removal.

Servicing should always include the removal of any debris from
the condensate pipe and siphon.

1. Unscrew the screws [1];

2. Push the casing [2] upwards and remove it;

3. Unscrew the two screws [3] and hinge downwards the
control panel [4];

4. After the regulations, close the boiler repeating everything
in the other sense, carefully hooking the casing to the
lugs [5].

After completing any servicing of gas carrying components, AL­WAYS test for gas soundness and carry out a functional test of
the controls.

12.3 Burner

Refer to Diagram 12.4.

- Undo main gas supply nut from burner.

- Pull main burner forward, pull off the ignition and fl ame sense
leads from the electrodes and remove burner from boiler.

5

2

3

1

4

Diagram 12.3

12.4 Heat Exchanger

Remove loose debris from inside the heat exchanger using a
soft brush and vacuum cleaner.

12.5 Condensate Trap

The condensate trap does not normally need removing during
servicing.

To fl ush the condense drain carefully pour water into the fl ue
heat exchanger and check that water fl ows freely to drain.

12.6 Combustion chamber seal check

Check the condition of the seal and replace if worn or dam­aged.

To replace remove the old seal and thoroughly clean the casing
surfaces. Fit the new seals.

Diagram 12.4

41

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12 Servicing

1

25

24

23

22

21

20

19

2
3

4
5

6
7

8
9

10

11

12

1 Flue overheat thermostat

(manual reset control)

2 Air pressure switch

3 Fan

4 Automatic air vent

5 Expansion vessel

6 Flue hood

7 Heat exchanger

8 Flame sense electrode

9 Ignition electrode

10 Electronic igniter

11 Safety valve 3 bar

12 Gas valve

1318 141517 16

13 Domestic plate-to-plate heat exchanger

14 Priority pressure switch

15 Hydraulic 3-way valve

16 DHW temperature sensor

17 Condensate trap

18 Drain valve

19 Pump

20 Low water pressure switch

21 Heating circuit temperature sensor

22 Burner

23 Overheat thermostat

24 Flue heat recuperator

25 Flue overheat thermostat (probe)

Diagram 12.5

42

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13 Fault Finding

NOTE:

Before trying to operate the boiler make sure that :

• All gas supply cocks are open and that the gas supply has
been purged of air.

• There is a permanent mains supply to the boiler.

• There is a heating demand from the external controls.

WARNING

Always isolate the boiler from the electrical supply before car­rying out any electrical replacement work.

Always check for gas soundness after any service work.

Electrical Testing

Should there be any doubt about the voltage supply to any of
the components, it is possible to carry out a simple electrical
test.

Important: On completion of the Service/Fault Finding tasks
which have required the breaking and remaking of the electri­cal connections the earth continuity, polarity, short circuit and
resistance to earth checks must be repeated using a suitable
multimeter.

To carry out the electrical test, gain access, as follows:

Hinge down the control box and unscrew the rear cover’s
screws to remove and gain access. Refer to the wiring diagram

13.1.

43

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13 Fault Finding

Electric diagram

ACC Electronic igniter
AO Time clock power supply
C Pump
CO Time clock contact
EA Ignition electrode
ER Flame sense electrode
F1 Fuse (2 A)
MOD Modulator
MF Priority pressure switch
MPV Flue pressure switch
MV Fan motor

Colours
abbreviations:

BK Black
BN Brown
BU Blue
GN Green
GNYE Green-Yellow
GY Grey
OG Orange
RD Red
VT Violet
WH White
YE Yellow

PSA Low water pressure switch

(“N.O.” contact closed = in pressure)
SR NTC sensor, heating
SS NTC sensor, DHW
TA Voltage-free Contact for generic

Room Thermostat or Cronothermostat

(safety extra low voltage SELV)
TC Condensate trap overfl ow sensor
TF Flue overheat thermostat
TS Overheat thermostat
VG Gas valve (coils)

44

Diagram 13.1

Supplied By www.heating spares.co Tel. [phone]

14 Replacement of Parts

14.1 General

Refer to Diagram 14.3 for the overall view of disassembled
items.

Replacement of parts must be carried out by a competent per­son.

Before replacing any parts the boiler should be isolated from
the mains electric supply and the gas should be turned off at
the service cock on the boiler, see diagram 14.1.

Ensure that components with electrical connections are dis­connected before removal.

Unless stated otherwise parts are replaced in the reverse order
to removal.

After replacing any parts always test for gas soundness and if
necessary carry out functional test of the controls.

14.2 Draining of Boiler Heating Circuit

Drain down the Heating Circuit of the boiler only, by closing the
heating fl ow and return isolating valves. Attach a length of hose
to the drain point and open the drain valve, see diagram 14.2.

After replacing parts, close the drain valve and remove the
hose. Open the heating fl ow and return isolating valves and re­fi ll, vent and pressurise the heating circuit, refer to section 11.

Check for leaks.

14.3 Draining of Boiler Hot Water Circuit

Drain the Domestic Hot Water circuit by closing the cold-water
isolation valve, see diagram 14.1.

Open one or more hot water taps to drain the hot water circuit.

After replacing parts open the cold-water isolation valve and
slowly open a hot water tap to remove air. Close the hot water
tap and check for any leaks.

HEATING

RETURN

VALV E

HEATING

FLOW

VALV E

COLD

WATER

VALV E

GAS

COCK

Diagram 14.1

45

Diagram 14.2

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14 Replacement of Parts

46

Diagram 14.3

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15 Spare Parts

47

Diagram 15.1

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16 Manual Handling

IMPORTANT. With regards to the Manual Handling Opera-

tions, 1992 Regulations, the following lift operation exceeds the
recommended weight for a one man lift.

General recommendations when handling

Clear the route before attempting the lift.
Ensure safe lifting techniques are used – keep back straight – bend us­ing legs. Keep load as close to body as possible. Do not twist – repo­sition feet instead. If 2 persons performing lift, ensure co-ordinated
movements during lift. Avoid upper body/top heavy bending - do not
lean forward/sideways. Recommend wear suitable cut resistant gloves
with good grip to protect against sharp edges and ensure good grip.
Always use assistance if required.

Removal of carton from delivery van

Recommend 2 person lift or 1 person with use of sack truck. If 1 person
is performing lift, straddle the load, tilt and place carton into posi­tion on truck. Recommend secure appliance onto truck with suitable
straps. Ensure safe lifting techniques are used – keep back straight
– bend using legs. Keep load as close to body as possible. If 2 persons
performing lift, ensure co-ordinated movements during lift. Always use
assistance if required.

Carriage of carton from point of delivery to point
of installation – ground fl oor.

Recommend 2 person lift or 1 person with use of sack truck. If 1 person
is performing lift, straddle the load, tilt and place carton into position on
truck. Recommend secure appliance onto truck with suitable straps.
Ensure safe lifting techniques are used – keep back straight – bend
using legs. Keep load as close to body as possible. If 2 persons per­forming lift, ensure co-ordinated movements during lift. Clear the route
before attempting the lift. If removing boiler from truck straddle the load
and tilt forwards to facilitate secure grip. Ensure safe lifting techniques
are used – keep back straight – bend using legs. Do not twist – repo­sition feet instead. Take care to avoid trip hazards, slippery or wet
surfaces and when climbing steps and stairs. Always use assistance if

required.

Carriage of carton from point of delivery to point
of installation – fi rst or higher fl oor, cellar.

Recommend 2-person lift or 1 person with use of sack truck. If 1 person
is performing lift, straddle the load, tilt and place carton into position on
truck. Recommend secure appliance onto truck with suitable straps.
Ensure safe lifting techniques are used – keep back straight – bend us­ing legs. Keep load as close to body as possible. If 2 persons perform­ing lift, ensure co-ordinated movements during lift. Avoid upper body/top
heavy bending - do not lean forward/sideways. Clear the route before
attempting the lift. If removing boiler from truck straddle the load and
tilt forwards to facilitate secure grip. Ensure safe lifting techniques are
used – keep back straight – bend using legs. Do not twist – reposition
feet instead. Take care to avoid trip hazards, slippery or wet surfaces
and when climbing steps and stairs. Always use assistance if required.

Carriage of carton from point of delivery to point
of installation – roofspace.

Recommend 2-person lift. Ensure co-ordinated movements during
lift. Avoid upper body/top heavy bending - do not lean forward/side­ways. Clear the route before attempting the lift. Take care to avoid trip
hazards, slippery or wet surfaces and when climbing steps and stairs.
When transferring appliance into roofspace, recommend 1 person to be
in roofspace to receive the appliance and other person to be below to
pass up and support appliance. Ensure safe lifting techniques are used
– keep back straight – bend using legs. Keep load as close to body as
possible. Always use assistance if required. It is assumed safe access,
fl ooring and adequate lighting are provided in the roof space. It is
recommended a risk assessment of the roof space area be carried out
before moving the appliance into the area to take into account access,
stability of fl ooring, lighting and other factors, and appropriate measures
taken.

Unpacking of appliance from carton.

Recommend 2 persons unpack appliance from carton. Always keep
working area clear. Recommend cut base end of carton and open car­ton fl aps, then tilt boiler forwards from its side onto its base and remove
carton by sliding up over the boiler. Ensure safe lifting techniques are

used – keep back straight – bend using legs. Keep load as close
to body as possible. Always use assistance if required. Dispose of
packaging in a responsible manner. Recommend wear suitable cut
resistant gloves with good grip to protect against sharp edges and
ensure good grip when handling appliance outside packaging.

Positioning of Appliance for Final Installation
– no obstructions.

Recommend 2 persons lift appliance to position into place. Fit bracket
securely onto wall before lifting appliance into position. Obtain fi rm
grip on front and sides of appliance, lift upwards, ensure stable bal­ance achieved and lift upwards to position in place on bracket. Ensure
safe lifting techniques are used – keep back straight – bend using
legs - when lifting load from fl oor level. Do not twist – reposition feet
instead. Keep boiler as close as possible to body throughout lift to
minimise strain on back. Ensure co-ordinated movements to ensure
equal spread of weight of load. Always use assistance if required.
Recommend wear suitable cut resistant gloves with good grip to
protect against sharp edges and ensure good grip when handling
appliance.

Positioning of Appliance for Final Installation
– above worktop, foreseeable obstructions etc.

Recommend 2 persons lift appliance to position into place. Fit bracket
securely onto wall before lifting appliance into position. Obtain fi rm grip
on front and sides of appliance, lift upwards, onto worktop if practicable.
Ensure stable balance achieved and lift upwards to position in place on
bracket. If 2 persons positioning onto bracket obtain fi rm grip at front
and sides/base of boiler. Ensure co-ordinated movements during 2
person lifts to ensure equal spread of weight of load. Ensure safe lifting
techniques are used – keep back straight – bend using legs - when lift­ing load from fl oor level. Do not twist – reposition feet instead. Keep
boiler as close as possible to body throughout lift to minimise strain on
back. Avoid upper body/top heavy bending - do not lean forward/side­ways. Always use assistance if required. Recommend wear suitable
cut resistant gloves with good grip to protect against sharp edges and
ensure good grip when handling appliance.

Positioning of Appliance for Final Installation –
within compartment etc. restricting installation.

Recommend 2 persons lift appliance to position into place, space per­mitting. Fit bracket securely onto wall before lifting appliance into po­sition. Obtain fi rm grip on front and sides of appliance, lift upwards,
onto worktop if practicable. Ensure stable balance achieved and lift
upwards to drop into place onto bracket. If 2 persons positioning onto
bracket obtain fi rm grip at front and sides/base of boiler. Ensure co­ordinated movements during 2 person lifts to ensure equal spread of
weight of load. If 1 person positioning onto bracket recommend obtain
fi rm grip supporting base of boiler. Ensure safe lifting techniques are
used – keep back straight – bend using legs - when lifting load from
fl oor level. Do not twist – reposition feet instead. Keep boiler as close
as possible to body throughout lift to minimise strain on back. Always
use assistance if required. Recommend wear suitable cut resistant
gloves with good grip to protect against sharp edges and ensure good

grip when handling appliance.

Positioning of Appliance for Final Installation
– in roof space restricting installation.

Recommend 2 persons lift appliance to position into place, space per­mitting. Fit bracket securely onto wall before lifting appliance into po­sition. Obtain fi rm grip on front and sides of appliance, lift upwards,
ensure stable balance achieved and lift upwards to drop into place
onto bracket. If 2 persons positioning onto bracket obtain fi rm grip at
front and sides/base of boiler. Ensure co-ordinated movements dur­ing 2 person lifts to ensure equal spread of weight of load. If 1 per­son positioning onto bracket recommend obtain fi rm grip supporting
base of boiler. Ensure safe lifting techniques are used - keep back
straight – bend using legs - when lifting load from fl oor level. Do not
twist – reposition feet instead. Keep boiler as close as possible to body
throughout lift to minimise strain on back. Always use assistance if re­quired. Recommend wear suitable cut resistant gloves with good grip
to protect against sharp edges and ensure good grip when handling
appliance. It is recommended a risk assessment of the roof space
area be carried out before moving the appliance into the area to take
into account access, stability of fl ooring, lighting and other factors, and

appropriate measures taken

.

48

Supplied By www.heating spares.co Tel. [phone]

Installation,

Commissioning and

Service Record

Supplied By www.heating spares.co Tel. [phone]

982790002/000

Supplied By www.heating spares.co Tel. [phone]

Supplied By www.heating spares.co Tel. [phone]

Glow-worm, Nottingham Road, Belper, Derbyshire. DE56 1JT

www.glow-worm.co.uk

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