Glow-worm Betacom C User Manual
Betacom
Installation and Servicing
24c
G.C. No. 47-019-08
30c
G.C. No. 47-019-09
High Efficiency
Condensing Combination
Boilers
22
21
23
20
24
19
1
80 90
30 40 50 60 70
ON
2
3
1
4
0
bar
bar
18
2
17
3
16
1
4
15
0
5
14
6
13
7
12
8
11
9
10
www.glow-worm.co.uk
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. 01773 824639
Fax: 01773 820569
To register your Glow-worm appliance
call:
0800 0732142
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided
with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s
instructions by a competent person approved at the time by the Health and Safety Executive and that it meets the requirements of
the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations
and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of
Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme.
Visit www.central heating.co.uk for more information.
2
These instructions consist of, Installation, Servicing, Fault Finding, Replacement of Parts
and Spares. 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.
CONTENTS DESCRIPTION SECTION PAGE
INTRODUCTION
INSTALLATION
Warnings
Important Information
Statutory Requirements
Boiler Design
Safety Devices
Servicing, Maintenance and Spare Parts
Boiler Specication
Boiler Components
Boiler Dimensions and Hydraulic Schematic
Boiler Location, Clearances and Ventilation
Flue Options and Terminal Clearances
Water System - Heating
Water System - Domestic Hot Water
Installation Preparation
Boiler Fixing / Gas / Water / Safety Discharge Connection
System Pipes and Condensate Connection
Condensate Connections
Telescopic Flue - Length, Preparation and Installation
Standard Flue - Length, Preparation and Installation
Vertical Flue - Length, Preparation and Installation
Twin Flue - Length, Preparation and Installation
Plume Management Kit
Electrical Connection
Commissioning
2
3
4
5
5
6
7
8
8
9
9
9
9
9
10
11
4
4
5
6
6
7
8
9
10
11
12
14
15
16
18
19
20
21
25
29
32
35
35
38
MAINTENANCE
Servicing
Fault Finding
Replacement of Parts
Spare Parts
Manual Handling
Declaration of Conformity
12
13
14
15
16
17
46
50
56
64
66
67
3
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.
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.
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.
CAUTION:
While there are no substances harmful to health contained
within this boiler, some component parts of the boiler
(insulation pads, gaskets and rope seals) are manufactured
from man made bres. When damaged or broken these bres
may cause a temporary irritation. High dust levels may irritate
eyes and upper respiratory system. It is important therefore,
that sensible precautions are applied when exchanging
components.
If you have a history of skin complaint you may be susceptible
to irritation.
Normal handling should not cause discomfort, but follow good
hygiene and wash your hands before eating, drinking or going
to the lavatory.
If you suffer irritation to the eyes or severe irritation to the skin
seek medical advice.
Manual Handling
With regards to the “Manual Handling Operations, 1992
Regulations”, the appliance exceeds the recommended
weight for a one man lift, refer to section 16 for more
information.
The handling of the boiler may involve lifting, pushing and
pulling, the use of a sack truck may be required.
The following handling techniques and precautions should be
considered:
- Grip the boiler at its base
- Be physically capable
- Use safety clothing where appropriate, e.g. gloves, safety
footwear.
Ensure safe lifting techniques are used
- Keep back straight.
- Avoid twisting at the waist.
- Avoid upper body/top heavy bending.
- Always grip using the palm of the hand.
- Use designated hand holds.
- Keep load as close to body as possible.
- Always use assistance if required.
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 ETCI rules.
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 identied 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).
Testing and Certication
This boiler is tested and certicated 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 certication, boiler warranty and may also infringe the
current issue of the statutory requirements.
4
Statutory Requirements
CE Mark
This boiler meets the requirements of Statutory Instrument,
No. 3083 The Boiler (Efciency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on
the efciency requirements for new hot water boilers red with
liquid or gaseous fuels.
Type test for purposes of Regulation 5 certied by:
Notied body IMQ 51BP2727 CE Directives 90/396/EEC.
51BP2728DR CE Directives 92/42/EEC.
Product/production certied by:
Notied body IMQ 51BP2727 CE Directives 90/396/EEC.
51BP2728DR CE Directives 92/42/EEC.
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.
IMPORTANT
Where no British Standards exists, materials and equipment
should be t for their purpose and of suitable quality and
workmanship.
The installation of this boiler must be carried out by a
competent person approved at the time by the Health and
Safety Executive and in accordance with the rules in force in
the countries of destination.
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 specication (CheSS)
and
2) Controls for domestic central heating system and hot water.
BRECSU.
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 internal diameter of the gas supply from the governed
meter to the boiler’s gas inlet connection must not be less
than 22mm.
The supply from the governed meter must be of adequate size
to provide a steady inlet working pressure of 20mbar (8in wg)
(for natural gas) at the boiler. In addition to the demand of any
other gas appliances being serviced from that supply.
On completion, test the gas installation for tightness using the
pressure drop method and suitable leak detection uid, purge
in accordance with the above standard.
Domestic Hot Water
All domestic hot water circuits, connections, ttings must be
in accordance with the relevant standards and water supply
regulations.
GB: Guidance G17 to G24 and recommendation R17 to R24
of the Water Regulations Guide.
IE: The current edition of I.S.813 “Domestic Gas Installations”.
Statutory Requirements
In GB, the installation of the boiler must comply with the
requirements of the current issue of BS6798 and be carried
out by a competent person approved at the time by the
Health and Safety Executive and as described in the following
regulations:
The manufacturer’s instructions supplied.
The Gas Safety (Installation and Use) Regulations.
The appropriate Buildings Regulations either The Building
Regulations, The Building Regulations (Scotland), The
Building Regulations (Northern Ireland).
The Water Fittings Regulations or Water byelaws in Scotland.
The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).
The Current I.E.E. Wiring Regulations.
Where no specic 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 approved at the time by the Health and Safety
Executive 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.
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.
IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.
Heating System
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.
5
Boiler Design
Boiler Design
These boilers are 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
tted within the boiler.
The appliance has a built in frost protection device that
protects the boiler from freezing.
Once the controls are set the boiler operates automatically.
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 reset the
appliance. If the boiler does not resume normal operation
after this call your Installation/Servicing company or
Glow-worm service.
Overheating Safety
The boiler software is designed to recognise the potential for
an overheat (Boiler Lockout). The temperature of the water
owing from the primary heat exchanger is monitored by an
overheat thermostat located on the outlet pipe. If the water
temperature gets too hot the switch opens, cutting off the
electrical supply to the gas valve and causing the boiler to
‘Lockout’. Once activated the boiler has to be manually re-set
by switching the control knob off (for 15 seconds) and on
again.
Low Water Pressure
A hydraulically operated primary pressure sensor monitors
water pressure or water shortage in the primary hydraulic
circuit and will switch the boiler off if the pressure is below
0.3bar. The boiler will not operate until the circuit has been
re-pressurised.
Flue Blockage
For HK type; an air pressure switch situated in the boiler’s
fan compartment monitors the boiler’s ue operation. If a
partial obstruction within the ue occurs the fan will continue
operating but the boiler’s burner will shut down until the
blockage is cleared.
Condensate Drain
A plastic drain pipe must be 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 9 for more details.
Pluming from ue terminal
Like all condensing boilers this appliance will produce a plume
of condensation from the ue terminal in cool weather. This is
due to the high efciency and hence low ue gas temperature
of the boiler.
This is normal and not an indication of a fault.
Frost protection
The boiler’s control unit has in-built frost protection device
that res the boiler’s burner when the temperature of primary
hydraulic water falls below 6°C. The device works irrespective
of any room thermostat setting and will protect the complete
heating system. On reaching a water temperature of 15°C the
boiler reverts to normal operation.
NOTE: If the boiler will not be used for long periods of time
during cold weather, in order to avoid freezing the electric
supply must be left ON and all the central heating isolation
valves must be left open. The internal frost protection device
will then operate the boiler if the temperature falls too low.
However, if the electrical supply is to be turned off the boiler,
the heating system and domestic hot water circuit must be
drained.
Safety Discharge Valve
A safety discharge valve and discharge pipe are 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.
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.
NOTE: If the boiler fails to resume normal operation and
all external controls are calling for heat, then call your
Installation/Servicing company or Glow-worm service.
6
Servicing, Maintenance and Spare Parts
Servicing and Maintenance
To ensure the continued efcient 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 all cases the boiler must be serviced at least once a
year.
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.
“Benchmark” scheme
Glow-worm support the Benchmark initiative. It is very
important that the Installation, Commissioning and Service
Record is completed by the installation engineer and handed
over to the user.
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 specication 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.
Please quote the name of the appliance, this information 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.
7
Boiler Specication
Boiler Design
These boilers are 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
tted within the boiler.
BOILER SPECIFICATION 24c 30c
Lift weight 37 kg (82 Ib) 38 kg (84 Ib)
Total weight (installed) 40 kg (88 Ib) 41 kg (90 Ib)
Gas connection Ø O.D. 22mm. copper 22mm. copper
Heating flow and return connection Ø O.D. 22mm. copper 22mm. copper
Domestic hot water connection Ø O.D. 15mm. copper 15mm. copper
Condensate connection Ø I.D. 21.5mm. plastic 21.5mm. plastic
Safety valve discharge connection Ø O.D. 15mm. copper 15mm. copper
Heating circuit safety valve (preset) 3.5 bar (53.5 Ibf/in2) 3.5 bar (53.5 Ibf/in2)
Heating system minimum pressure 0.8 bar (11.6 Ibf/in2) 0.8 bar (11.6Ibf/in2)
Heating system nominal pressure 1.5 bar (21.7 Ibf/in2) 1.5 bar (21.7 Ibf/in2)
Maximum domestic water supply pressure 8 bar (116 Ibf/in2) 8 bar (116 Ibf/in2)
Minimum domestic water supply pressure 0.25 bar (3.6 Ibf/in2) 0.25 bar (3.6 Ibf/in2)
Maximum domestic hot water temperature 64ºC 64ºC
Maximum central heating temperature 85ºC 85ºC
o
Maximum domestic hot water output at 35
Expansion vessel capacity 7 litres (1.53 gallons) 8 litres (1.76 gallons)
Expansion vessel pre-charge pressure 1.0bar (14.6 Ibf/in2) 1.0bar (14.6 Ibf/in2)
Minimum flow rate around the 776 L/hr. 1032 L/hr.
central heating circuit at 35 rise
Electrical supply 230V~50Hz fused 5A 230V~50Hz fused 5A
Maximum power comsumption 220 Watt 220 Watt
EN60529 IP clasification IPX4D IPX4D
Internal fuse rating on main PCB 2A 2A
Gas supply (governed meter only - NG)* G20 - NG /G31 - Propane G20 - NG /G31- Propane
Gas category II
Inlet gas working pressure - NG 20 mbar 20 mbar
Heat input maximum 25.7 kW. 28.5 kW.
Heat output maximum 24.7 kW. 27.6 kW.
Heat input minimum 11 kW. 11 kW.
Heat output minimum 10.2 kW. 10.2 kW.
Usefull efficiency at 100% load 96% 96.8%
Usefull efficiency at 30% load 102.4% 103.3%
Burner injector NG / LPG (G31) 1.20 mm / 0.75mm 1.15 mm / 0.75mm
Burner pressure maximum NG** 12.5 mbar 14 mbar
Burner pressure minimum NG 2.5 mbar 2.3 mbar
SEDBUK rating Band B 86.0% Band 86.4%
NOx Class 3 Class 3
Flue Type C12-C32-C42-C52 C12-C32-C42-C52
Δ T 9.4
The appliance has a built in frost protection device that
protects the boiler from freezing.
Once the controls are set the boiler operates automatically.
L/min.
2H3P
10.5
L/min.
II
2H3P
14343
* See Commissioning section for NG (G20) to LPG (G31) conversion
** Installation to (G31) Propane is by conversion kit only
8
12
h
e
r
Condensing Unit (Turbo heat exchanger)
11
10
Boiler Components
e
t
a
t
r
A
13 14 15
14532
e
r
h
e
t
a
t
r
A
16
9
17
8
18
7
6
r
a
e
r
e
5
h
t
t
A
4
3
2
1
A
DCB
E
19
20
21
22
23
24
25
A - Heating Flow (22mm)
B - D.H.W. Outlet (15mm)
C - Gas Inlet (22mm)
D - Cold Water Inlet (15mm)
E - Heating Return (22mm)
Key
1 - D.H.W. Sensor
2 - Diverter Valve Motor
3 - Diverter Valve
4 - Condensate Trap
5 - Limit Thermostat
6 - Expansion Vessel (At rear of the boiler)
7 - Burner
8 - Flame Sensor Electrode
9 - C.H. Sensor (Heating Sensor)
10 - Combustion Chamber
11 - Primary Heat Exchanger
12 - Fan Hood
13 - Fan
14 - Air Pressure Switch
15 16 - Overheat Safety thermostat
17 - Ignition Electrode
18 - Heating Circuit– Pressure Safety Valve
19 - Secondary Heat Exchanger
20 - Automatic Air Vent
21 - Water Pressure Switch/Sensor
22 - Pump
23 - Gas Valve
24 - D.H.W. Flow Sensor
25 - Filter Valve (Below the pump)
9
2 Boiler Dimensions and Hydraulic Schematic
150
720
105
170
330
135
14334
2.1 Boiler Dimensions and Hydraulic
Schematic
All dimensions are given in millimetres (except as noted).
The general arrangement of the boiler is shown in diagram
2.1 and the hydraulic and gas schematics diagrams, showing
the central heating hydraulic circuit and domestic hot water
hydraulic circuit in diagram 2.2.
The data label is positioned on the control box back cover.
14335
130 130
CONDENSATE
CONNECTION
50
C
L
BOILER
86 86
98
30
SDV
outlet
10
151 151
405 24c
430 30c
CENTRAL HEATING
DOMESTIC WATER
Diagram 2.2Diagram 2.1
3 Boiler Location, Clearances and Ventilation
20
3.1 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.
3.2 Clearances
The boiler should be positioned so that at least the minimum
operational and servicing clearances are provided, see
diagram 3.1.
Additional clearances may be benecial around the boiler for
installation and servicing.
For ue installations where external access is not practicable,
consideration should be given for the space required to insert
the ue internally, which may necessitate clearance larger
than those specied in diagram 3.1.
3.3 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it
should be 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.
3.4 Combustible Material
The boiler and ue are suitable for installation onto and
through combustible materials provided that:-
1) The boiler must be sited at least 1m away from ammable
materials and heat sensitive walls must be protected by
appropriate insulation.
2) Minimum 5 mm clearance is maintained around the
circumference of the ue (air intake).
3) The combustible surface and xings are suitable for
supporting the load.
4) The minimum clearances from the boiler case are
maintained.
3.5 Room Ventilation
The boiler is room sealed so a permanent air vent is not
required.
3.6 Cupboard or Compartment Ventilation
If the boiler is installed in a compartment there must be
purpose made ventilation for cooling purposes.
Make sure the cupboard or compartment air vents are
positioned to be clear of obstructions at all times.
A compartment used to enclose the boiler must be designed
and constructed specically for this purpose.
An existing cupboard or compartment modied for the
purpose may be used. Refer to the current issue of BS6798
for guidance.
14344
20
600
20
200
20
2020
300
HI LO
Betacom 24c 128.5cm² 128.5cm²
Betacom 30c 142.5cm² 142.5cm²
KEY
NON COMBUSTIBLE MATERIAL
Diagram 3.1
11
4 Flue Options and Terminal Clearances
Top horizontal telescopic ue (Ø60/100)
Part No. A2043600 - Section 9, page 21
Top horizontal standard ue (Ø60/100)
Part No. A2043400 - Section 9, page 25
Plume Management Kit
basic set, white, concentric ue
(Ø60/100) - Part No. A2044100 for
use with Part No. A2043400 and Part
No. A2043600 - Section 9, page 35
12
Vertical Flue
Vertical Flue Adapter, concentric ue (Ø60/100)
Part. No. A2024600
Vertical ue terminal kit, concentric ue (Ø60/100)
Part. No. 2000460480 - Section 9, page 29
Twin Flue
Twin Flue Adapter, concentric ue (Ø80)
Part No. A2011000 - Section 9, page 32
Diagram 4.1
4 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
H* TO A BOUNDARY ALONGSIDE THE
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
4.1 Flue Options
There are various ue options to choose from as illustrated in
diagram 4.1. The ue lengths and installation are described in
section 9.
4.2 Flue Terminal Position
In GB the minimum acceptable siting dimensions for the
terminal from obstructions, other terminals and ventilation
openings are shown in diagram 4.2.
In IE the minimum distances for 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 ue outlet. This should be taken into consideration when
selecting the position for the terminal.
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 4.2. 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.
4.3 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 4.3.
A suitable guard is manufactured by: Tower Flue Components
Morley Rd.
Tonbridge
Kent TN9 1RA.
Size: 280mm x 280mm x 270mm.
12325
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 4.2
Diagram 4.3
13
5 Water System - Heating
5.1 General
The boiler is designed to operate on fully pumped,
pressurised sealed systems operating at a maximum of 3bar
pressure and maximum design ow temperature of 85°C.
5.2 Safety Valve
The safety valve is an integral part of the boiler and it cannot
be adjusted.The pipe from the safety discharge valve must
not discharge above an entrance, window or any type of
public access area.
5.3 Expansion Vessel
The boiler’s integral expansion vessel with a capacity of 7
litres (1.5 gallons), is pre-charged to a pressure of 0.5bar
and will accommodate a system volume of 125 litres at an
average water temperature of 75°C and maximum system
pressure of 3 bar. NOTE: The expansion vessel volume
depends on the total water system volume and the initial
system design pressure. In GB, Guidance on vessel sizing is
also given in the current issue of BS5449 and BS7074 Part 1.
In IE, current edition of I.S.813 “Domestic Gas Installations”.
If the system volume is more than 125 litres. an additional
expansion vessel must be tted to suit the size of the system.
A typical installation of an additional pressure vessel is shown
in diagram 5.1.
5.4 Flow Rate
If it is necessary to alter the ow rate, the system can be
tted with a lockable balancing valve in the main ow or
return pipes shown as valve “A” in diagram 5.1. The ow rate
through the boiler must not be allowed to fall below that given
in Boiler Specication Table.
The heating circuit should be designed and balanced to give a
20°C temperature rise across the boiler ow and return.
5.5 Water Treatment
Existing system- It is ESSENTIAL that prior to installing the
new boiler the system is thoroughly ushed.
New system- For optimum performance after installation, the
boiler and its associated central heating system should also
be ushed.
Flushing should be carried out in accordance with BS7593:
2006 using a cleanser such as Sentinel X300 or X400, Fernox
Restorer or Salamander corrosion guard cleaner.
IMPORTANT: Ensure all cleanser is removed from the whole
system before adding an inhibitor.
Although the boiler is designed to inhibit the formation of
scale, in hard water areas above 200mg/l, a proprietary scale
reducer should be tted in the cold water supply to the boiler.
Failure to comply with this requirement may invalidate your
guarantee. Refer to the current issue of BS 5449 and BS
7593 on the use of inhibitors in central heating systems.
14561
Diagram 5.1
5.6 General
On installation it is important to ensure that the heat
exchanger is not a natural collecting point for air and where
possible, the system pipe work should have a gradient to
ensure any excess air is carried naturally to other purpose
made, air release points.
In high water volume systems or under oor heating systems
where prolonged operation of the boiler is expected at
temperatures below 600C, a by-pass must be installed on the
boiler outlet in order to prevent condensation forming inside
the boiler body. Failure to comply with this requirement will
invalidate the manufacturer’s guarantee.
5.7 Bypass
The system’s water must always be allowed to circulate
whenever the circulation pump is running. A return by-pass
must be provided.
NOTE: It is no longer permissible to use non-thermostatic
radiator valves to allow by-pass through a radiator.
Diagram 5.2 shows the pump head remaining for the heating
system depending on the bypass setting and the speed
setting of the pump, see section 12 Commissioning.
Ensure that under no circumstances does the ow rate drop
below the gure specied, refer to Boiler Specication Table.
5.8 Filling the Sealed System
With water via the lling loop, see diagram 5.3, (the lling loop
is not supplied with the boiler).
14
5.9 Draining Points
Draining taps must be provided at all low points of the system,
which will allow the entire system to be drained.
Draining taps shall be to the current issue of BS2879.
5 Water System - Domestic Hot Water
H (m)
5.10 Water Pressure
To obtain the best hot water performance from your boiler it is
suggested that the cold water supply to the boiler is the rst
draw off from the incoming mains supply.
NOTE: The boiler will not operate unless there is a minimum
pressure of 0.25 bar (3.6 Ibf/in2) with a ow rate of 2.5 l/min.
The minimum working pressure to obtain the maximum
domestic ow is:-
24c 0.7 bar (10.15 Ibf/in
30c 0.7 bar (10.15 Ibf/in
The maximum working pressure of the domestic hot water
circuit is 8 bar. If the cold water supply pressure exceeds this,
then a pressure-reducing valve must be tted in the supply to
the boiler.
Where cold water mains are tted with a water meter, check
valve(s) or loose jumper stopcock, a domestic hot water mini-
expansion vessel may need to be tted.
To obtain the best hot water performance from your boiler it is
suggested that supplies to faucets are run in 15mm copper,
as short as possible and where practical, be insulated to
reduce heat loss.
2
)
2
)
5.11 ‘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 tted,
refer to the manufacturer’s instructions or consult the local
water company for additional advice.
7
6
5
4
3
2
1
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
QH Chart
Q (m
Diagram 5.2
3
14562
/h)
14024
Diagram 5.3
15
6 Installation Preparation
CHECK IF 230V thermostat plug is
required to t to PCB board.
WALL HANGING
BRACKET
SEALING
WASHERS
(5 OFF)
WALL
TEMPLATE
CONDENSATE
OUTLET PIPE
6.1 Appliance Pack
Please check the contents of the carton:
Appliance, Isolation Valves, Wall Hanging Bracket,
Wall Template, Service Installation and User Manual,
Guarantee Card and Benchmark Log Book, see diagram 6.1.
(Literature and appliance not illustrated)
Handling
IMPORTANT: With regards to the Manual Handling
Operations, 1992 Regulations, the following lift operation
exceeds the recommended weight for a one man lift, refer to
section 17 Manual Handling.
To remove the appliance, refer to diagram 6.2.
1. Carefully slit or remove the sealing tape being
careful not to scratch the appliance door.
2. Fully open the carton lid and remove any instructions
and components.
3. Read the instructions carefully before installation of
the appliance.
4. Roll the carton onto its open face.
5. Lift the carton free of the inner packaging.
6. Remove the mounting bracket and valve package.
14339
COLD WATER
FILTER
D.H.W
OUTLET
C.H. ISOLATION
VALVE RETURN
COLD WATER
ISOLATION VALVE INLET
GAS ISOLATION VALVE
SAFETY
DISCHARGE
C.H. ISOLATION
PIPE
VALVE FLOW
Diagram 6.1
7. Stand the boiler on its base within the expanded
polystyrene block and remove the top packaging piece.
8. If you wish to remove the expanded polystyrene base lie
the appliance on its back to do so.
6.2 Site Requirements
The boiler mounting wall should be suitable for the weight of
the appliance and be true and at.
NOTE: Due to the varied site conditions we do not supply
xings and advise that the installer should supply those which
are suitable.
16
1 2
14594
5
3
4
Diagram 6.2
6 Installation Preparation
6.3 Wall Template
Take the wall template from the document pack and place in
the desired position on the wall, giving due consideration to
the required boiler clearances, see section 3, and the ue you
are tting.
Mark the position of the ue centre, if tting a side ue, extend
the ue centre line into the corner then 170mm along the
adjacent wall, see diagram 6.3.
For extended side ues, the ue hole centre should be
determined by extending the dashed inclined line on the
template to the side wall, then 149mm along the adjacent
wall, see diagram 6.2. This dashed line is drawn at 44mm/
metre (2.5°) rise from the boiler.
To allow for the 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 ue hole.
6.4 Flue Hole Cutting
External access ue installation can use a 105mm diameter
core drill.
Internal access only ue installation will need a 125mm
diameter core drill.
NOTE: The ue is designed with an internal fall of 44mm/
metre (2.5°), therefore the hole can be drilled horizontally.
If 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.
14549
Diagram 6.3
6.5 Wall Hanging Bracket Assembly
The Wall Hanging Bracket is supplied in the main boiler
packaging.
Reposition the wall template over the ue hole and mark the
position of the xing holes for the hanging bracket.
NOTE: Due to the varied site conditions we do not supply
xings and advise that the installer should supply those which
are suitable.
Drill xing holes using a 8.5mm. drill bit and insert suitable
wall plugs. Secure the wall hanging bracket to the wall.
17
7 Boiler xing, Gas / Water / Safety Discharge Connections
14347
ISOLATION VALVES SHOWN CLOSED
7.1 System connection
Connect the isolation valves including sealing washers and
cold water inlet lter to the boiler ensuring the washers are
tted correctly, see diagram 7.1.
Make sure the isolation valves are closed.
7.2 Safety Discharge Pipe
Connect the safety discharge pipe, see diagram 7.2.
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.
To ease future servicing it is advisable to use a compression
type tting to extend the safety discharge valve tube.
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.
7.3 Boiler Hanging
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 onto the hanging bracket making sure the
boiler is located in the boiler mounting slots, see diagram 7.3.
IMPORTANT: With regards to the Manual Handling
Operations, 1992 Regulations, the following lift operation
exceeds the recommended weight for a one man lift, refer to
section 17 Manual Handling.
VIEWED FROM THE
REAR OF THE BOILER
Diagram 7.1
14348
Diagram 7.2
14346
18
Diagram 7.3
8 System Pipes and Condensate Connections
8.1 Condensate Trap Connection
A exible condensate outlet pipe is supplied and should be
used to couple the condensate trap to a 22mm to 25mm O.D.
non corrosive plastic pipe (overow pipe), see diagram 8.1.
NOTE: the pipe should have a fall of a least 2.5o 44mm/metre
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 8.3.
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 75mm high trap inside
the boiler. Fitting an extra trap may cause the boiler siphon to
work incorrectly.
Refer to BS5546 or BS6798 for advice on disposal of boiler
condensate.
8.2 System Pipes Connection
Plumb gas and water system pipe work up to the isolation
valves using olives supplied, see diagram 8.2.
Do not subject isolation valves to heat.
The whole of the gas installation, including the meter, should
be inspected, tested for tightness and purged in accordance
with the current issue of BS6891 and in IE the current edition
of I.S.813 “Domestic Gas Installations”.
14527
CONDENSATE
TRAP
CONDENSATE
OUTLET PIPE
Diagram 8.1
14552
ISOLATION VALVES SHOWN CLOSED
Diagram 8.2
19
8 Condensate Connections
13000
20
Diagram 8.3
9 Telescopic Flue - Length, Preparation and Installation
Horizontal Telescopic Flue
14350
9.1 Flue Length and Restrictors
The maximum permissable horizontal ue length is 2.5 metres
plus the ue terminal assembly, this can be achieved by use
of the accessories, see diagram 9.3.
However should an additional 90º or 2 x 45º elbows be used
then the length MUST be reduced by 1 metre.
The diagram 9.1 shows the length achievable by using the kit
A2043600.
When extension pipes are used the ue system must be
designed to have a continuous fall to the boiler of at least 2.5º
44mm/metre to allow condensate to run back into the boiler
and out via the condensate drain.
The ue can be installed from inside the building, when
access to the outside wall face is not practicable.
The ue restrictor is supplied in the documentation pack, the
correct size is supplied for the boiler output:Betacom 24c - 83mmØ
Betacom 30c - 85mmØ
The flue restrictor must be fitted in the flue adaptor for,
concentric flue installations less than 1 metre and twin flue
installations less than 2 metres equivalent length.
Full instructions are provided in the documentation pack.
14470
Diagram 9.1
21
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