Glow-worm Economy Plus 60F Instructions For Use, Installation & Servicing

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

Instructions for Use

Installation and Servicing

T o be left with the user

60F

G.C. No. 41 319 63

221504A.11.98

3558

Fanned Flue Boilers

BS 6332
BS 5258

This is a Cat I2H Appliance

Reference in these instructions to British Standards and Statutory

Regulations/Requirements apply only to the United Kingdom.

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

For Ireland the rules in force must be used.

Card. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety

(Installation and Use) Regulations, be handed to the user on completion of the installation.

Guarantee Registration

Thank you for installing a new Glow-worm appliance in your home.

Glow-worm appliances' are manufactured to the very highest standard so we are pleased

to offer our customers' a Comprehensive First Year Guarantee.

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

return as soon as possible.

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

Service number 01773 828100.

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

✔

All replacement parts

❏

✔

All labour charges

❏

All call-out charges

✔

❏

One Contact Local Service

REGISTER YOUR GLOW-WORM APPLIANCE

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0181 380 2555

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

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: [phone] Fax: [phone]

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

Important Information

Testing and Certification

This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without
permission, in writing, from Hepworth Heating Ltd.

Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the
current issue of the Statutory Requirements, see Section 1.4.

CE Mark

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

Type test for purposes of Regulation 5 certified by: Notified body 0086.
Product/productioncertifiedby: Notified body 0086.
The CE mark on this appliance shows compliance with:

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

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

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

INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.

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

CERAMIC FIBRE/INSULATION PADS, GLASSYARN.

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

THERMOSTATS

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

CUT-OFF DEVICES

These contain activated charcoal and a very small amount of chlorodifluormethane in the sealed phial and capillary. If broken, under
normal circumstances the fluid does not cause a problem. If there is irritation to the eyes or skin then seek medical attention.

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

Introduction 3
Lighting the Boiler 4

General Data 1 5
Water Systems 2 7
Boiler Location 3 10
Flue 4 11
Preparation 5 13
Water Connection 6 18
Flue Assembly Installation 7 18
Gas Connection 8 20
Electrical Connection 9 20
Commissioning 10 21
Completion 11 24

SERVICING

Servicing 12 25
Fault Finding 13 26

INSTRUCTIONS

Replacement Parts 14 31
Spare Parts 15 35

221504A

2

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Instructions for Use

Introduction

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

The Economy Plus “F” Range are boilers designed to provide
central heating and indirect domestic hot water from a fully
pumped system with a fully indirect cylinder.

Important Notice

This boiler is for use only on natural gas G20 gas.

Gas Safety (Installation and Use) Regulations.

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

Gas Leak or Fault

If a gas leak or fault exists or is suspected, the BOILER MUST
BE TURNED OFF, including the electrical supply and MUST
NOT BE USED UNTIL THE FAULT HAS BEEN PUT RIGHT.
Advice/help should be obtained from your installation/servicing
company or the local gas undertaking.

Maintenance/Servicing

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

If this appliance is installed in a rented property 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.

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

To obtain service, please call your installer or Heatcall (Glow­worm’s own service organisation) using the telephone number
given on the case tray.

Boiler Clearances

If fixtures are positioned close to the boiler space must be left
as shown in diagram 1. Enough space must also be left in front
of the boiler to allow for servicing.

Boilers Installed in a Compartment or
Cupboard

If the boiler is installed in a cupboard or compartment do not
obstruct any ventilation openings.

Do not use the cupboard or compartment for storage.
Regularly make sure that the air vent openings are clear of

obstructions.

Cleaning

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

Clean the casing occasionally by wiping it over with a damp
soapy cloth or dry polishing duster.

Do not use an abrasive cleaner.

3540

150

DD

B

EE

A

PERMANENT
SURFACE

CLEARANCES

Diagram 1

Boiler Electrical Supply

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

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

BS7671.
The colours of three core flexible cable are:
Brown - live, blue - neutral, green and yellow - earth.
As the markings on your plug may not correspond with these

colours, continue as follows,
The wire coloured blue must be connected to the terminal

marked “N” or “Black”.
The wire coloured brown must be connected to the terminal

marked “L” or “Red”.
The wire coloured green and yellow must be connected to the

plug terminal marked “E” or “Green” or the earth symbol "

" .

Electrical Supply Failure

Failure of the electrical supply will cause the burner to go out.
Should this happen, operation of the appliance will normally
resume after the electrical supply is restored.

If the burner does not relight after an electrical supply failure the
overheat device may need resetting, refer to diagram 2, remove
the controls tray and press the reset button.

If the cutoff occurs again, turn the appliance off and contact your
installation/servicing company.

3540

3

221504A

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Instructions for Use

Data/Serial Number Label

The GC number of the appliance can be found on the Data label,
positioned at the top right of the inner cover.

The model name and serial number are located on the control
box cover, visible when the controls tray is removed.

To Turn the Boiler On
Sealed Water Systems.

CAUTION. A sealed water system must be filled and pressurised
by a competent person.

Only light the boiler when you are sure that the system and
boiler have been filled and pressurised.

The pressure gauge should show at least 0.7bar, anything less
than this figure could indicate a leak and you MUST contact your
installation/servicing company.

If there is any doubt about the boiler being full of water consult
your installation/servicing company.

All Systems

Turn the electrical supply on to the boiler and check that any
remote controls are set to your requirements (refer to
manufacturer’s instructions for these items).

Remove the controls tray by withdrawing it forwards.
Turn the boiler thermostat knob clockwise to any position

between “MIN” and “MAX”, see diagram 2. The maximum
setting is about 82

The boiler lighting operation is now automatic as follows:
The fan operates, followed by an ignition spark until the pilot is

lit. When the pilot is alight the ignition switches off and the main
burner lights. The flames can be seen through the viewing
window.

The main burner will remain alight until switched off by the boiler
thermostat or other remote control.

If the boiler thermostat is turned Off, by hand, wait at least 30
seconds before turning on again.

When the boiler goes off, both the pilot and main burner go out.
The automatic lighting sequence will operate again when heat

is required.
Refit the controls tray.

o

C (180oF).

VIEWING
WINDOW

CONTROLS TRAY

SERIAL No.

SETTING
POINT

OVERHEAT
CUT-OFF
RESET
BUTTON

BOILER THERMOSTAT CONTROL KNOB

BOILER CONTROLS

3560

Diagram 2

To Turn the Boiler Off

For short periods, turn thermostat control knob anti-clockwise
until “O” is against the setting point. To relight the main burner,
turn the thermostat knob clockwise to any setting between ”MIN”
and “MAX”.

For longer periods, turn the thermostat control knob anti­clockwise until “O” is against the setting point.

Switch off the electrical supply to the boiler.
To relight follow the sequence given above.

Protection Against Freezing

If the boiler is to be out of use for any long period of time during
severe weather conditions we recommend that the whole of the
system, including the boiler, be drained off to avoid the risk of
freezing up. Make sure that, if fitted, the immersion heater in the
cylinder is switched off.

If you have a sealed water system contact your installation/
servicing company as draining, refilling and pressurising must
be carried out by a competent person.

221504A

4

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360

122

45

1 General

WATER CONNECTIONS FLUE

TERMINAL

GAS CONNECTIONS

122

DETAIL

6472

=

=

55

*

42

600

60

86

from boiler top.

*

58mm from inner case top.

1.1 Important Notice

This boiler is for use only on G20 gas.
The boiler is delivered in one pack.
Wherever possible, all materials, appliances and components

to be used shall comply with the requirements of applicable
British Standards.

Where no British Standard exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.

This boiler must have fully pumped circuits, but is suitable for
use with open vented or sealed systems.

This boiler is not suitable for outdoor locations.

1.2 Sheet Metal Parts

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

1.3 Statutory Requirements

The installation of the boiler MUST be carried out by a competent
person in accordance with the relevant requirements of the
current issue of:

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

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

300

TABLE 1.

MODEL

LIFTING
WEIGHT

TOTAL
WEIGHT

WATER
CONTENT

GAS
CONNECTION

WATER
CONNECTION

ELECTRICITY
RATING

ELECTRICITY
SUPPLY

DATA LABEL

63

ECONOMY PLUS

60F

26.5Kg

(58.4lb)

33.0Kg

(72.8lb)

0.8Litre
(1.4pt)

Rc 1/2 (1/2 in. BSPT)

28mm copper,

flow at right, return at left

65W, internal fuse F1A.

240V~50Hz Fused 3A

On the inner case front

102

Diagram 1.1GENERAL ARRANGEMENT

DATA

5

221504A

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1 General

Detailed recommendations are contained in the current issue of
the following British Standards and Codes of Practice, BS4814,
BS5440 Part 1 and 2, BS5449, BS5546, BS6700, BS6798,
BS6891, BS7074 Part 1 and 2. BS7478, BS7593, BS7671.

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

1.4 B.S.I. Certification

The boiler is certificated to the current issue of BS6332 Part 1,
invoking the current issue of BS5258 Part 1 for performance
and safety. It is, therefore, important that no alteration is made
to the boiler, without permission, in writing, from Hepworth
Heating Ltd.

Any alteration that is not approved by Hepworth Heating Ltd.,
could invalidate the B.S.I. Certification of the boiler, the warranty
and could also infringe the current issue of the Statutory
Requirements.

1.5 General Data

The data label is positioned on the inner case visible when the
front panel is removed.

The serial number plate is positioned on the control box cover,
visible when the controls tray is removed.

The General Arrangement diagram 1.1 and all other dimensions
are given in millimetres.

General Data refer Table 1

1.9 Heating System Controls

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

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

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

TABLE 2.

RANGE RATING

NOMINAL

Btu/h

HEAT
INPUT(GROSS)

NOMINAL

Btu/h

HEAT
OUTPUT

BURNER

m bar

SETTING
PRESSURE

in.w.g

APPROX
GAS
RATE

kW

kW

m3h

ft3h

MODEL 60F

min medium max

63,290 68,750 74,070

18.55 20.15 21.71

50,000 55,000 60,000

14.65 16.12 17.58

9.4 11.2 13.0

3.8 4.5 5.2

1.8 1.9 2.1

63.0 68.5 74.0

1.6 Range Rating

The boiler is range rated and is factory set to maximum, it may
be adjusted to suit individual system requirements, refer to
Table 2.

1.7 Gas Supply

The gas installation must be in accordance with the current
issue of BS6891.

The supply from the governed meter must be of adequate size
to provide a steady inlet working pressure of 20mbar (8in wg) at
the boiler.

On completion, test the gas installation for soundness using the
pressure drop method and leak detection fluid, purge in
accordance with the current issue of BS6891.

1.8 Electrical Supply

WARNING. This boiler must be earthed.
All system components shall be of the approved type and wiring

shall comply with and be connected in accordance with the
requirements of the current issue of BS7671 and any applicable
local regulations.

Connection of the boiler and system controls to the mains
supply must be through a common isolator and must be fused
3A maximum. This method of connection should be, preferably,
by a fused double pole isolating switch, provided it has a
minimum contact separation of 3mm on both poles. This should
be readily accessible and preferably adjacent to the appliance.
It should supply the appliance only and be easily identifiable as
so doing.

Alternatively an unswitched shuttered socket outlet and 3A
fused 3 pin plug both to the current issue of BS1363 may be
used provided that they are not used in a room containing a bath
or shower.

Wiring to the boiler must be PVC insulated type to the current
issue of BS6500 Table 16, not less than 0.75mm

2

(24/0.20mm).

221504A

6

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2 Water System

Notes: Open Vented and Sealed Systems

See chart for pressure drop of the boiler diagram 2.1.

2.1 Draining Tap

The boiler is provided with a draining tap at the lower left hand
side of the heat exchanger, to be used for draining the heat
exchanger.

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

Draining taps shall be to the current issue of BS2879.

2.2 Safety Valve

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

2.3 Circulating Pump

The pump should be fitted in the flow pipe from the boiler and
have isolating valves each side, integral if possible.

A variable duty pump should be set to give a temperature
difference of 11
thermostat set at “MAX” which is about 82

0

C (20oF) between the flow and return with the

o

C (180oF), to give a

design flow rate as shown in Table 3.
High resistance microbore systems may require a higher duty

pump.

2.4 Bypass

A BYPASS MUST BE FITTED, see diagram 2.2 for a suitable
position.

The flow rate through the boiler must not be allowed to fall below
that given in Table 4.

Where the water system can allow the boiler and pump to
operate on bypass only, a bypass

must be placed at least 1.5m

away from the boiler.

2.5 Inhibitor

Attention is drawn to the current issue of BS5449 and BS7593
on the use of inhibitors in central heating systems.

If an inhibitor is to be used, contact a manufacturer for their
recommendations as to the best product to use.

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

2.6 Open (Vented) Water System

For an open (vented) system the boiler must be supplied from
an unrestricted water supply taken from a feed and expansion
cistern situated at a maximum height of 27.5metres (90ft)
above the boiler.

The cold feed supply must be 15mm minimum size.
The vent must rise continuously and be unrestricted.
It is important that the relative positions of the pump, cold feed

and open vent are as shown in diagram 2.2.

Flow rate (gallons/minute)

0123

4

56

2.0

1.5

1.0

0.5

Water pressure loss

(metres head of water)

0

5

0

10 15

20 25 30

Flow rate (litres/minute)

PRESSURE LOSS OF BOILER

450mm
MIN.
HEIGHT

78

70
60
50
40
30
20
10
0

35 40

Diagram 2.1

Open (vented) system.
Recommended
relationship between
pump, cold feed and
vent.

22 mm (MIN) VENT

FEED AND
EXPANSION
CISTERN

15mm (MINIMUM)
COLD FEED

0164M

Water pressure loss

(inches head of water)

0005M

TABLE 3.

DESIGN FLOW RATE at MAX OUTPUT

MODEL 60F 23.0L/min 5.1gal/min

TABLE 4.

MINIMUM FLOW RATE at MAX OUTPUT

MODEL 60F 16.4L/min 3.6gal/min

7

1150mm
MIN.

150
mm
MIN.

BOILER

22mm (MINIMUM)

15mm (MINIMUM)

BY-PASS WITH

BY-PASS WITH

LOCKSHIELD VALVE

LOCKSHIELD VALVE

ALTERNATIVE

PREFERRED

PUMP

150mm
MAX

RET.

RET.

CYLINDER

FLOW

Diagram 2.2OPEN VENTED SYSTEM

FLOW

HEATING

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2 Water System

2.7 Domestic Hot Water Cylinder

The hot water cylinder must be of the double feed fully indirect
type. Not the single feed self priming type.

2.8 Sealed Water Systems

The installation must comply with the appropriate requirements
of the current issue of BS5449, BS6759, BS6798, BS4814 and
BS7074 Part 1 and 2.

See diagram 2.3 for a suggested layout.

2.9 Safety Valve

A safety valve must be fitted to a sealed water system.
It shall be preset, nonadjustable with a lift pressure of 3bar,

incorporating seating of a resilient material, a test device and a
connection for drain.

The drain from the safety valve must be routed clear of any
electrical fittings and positioned so that any discharge can be
seen.

2.10 Expansion Vessel

A diaphragm type expansion vessel, conforming to the current
issue of BS4814 (see also BS7074 Part 1 and 2) must be
connected at a point close to the inlet side of the circulating
pump, see the diagrammatic layout, diagram 2.3, unless laid
down differently by the manufacturer.

The expansion vessel volume depends on the total water
system volume and the initial system design pressure. For any
system an accurate calculation of vessel size is given in the
current issue of BS7074 Part 1.

Example: For an initial system design pressure of 0.7bar, the
minimum total vessel volume required is 0.063xTotal System
volume.

Note: A higher initial design pressure requires a larger volume
expansion vessel.

Guidance on vessel sizing is also given in the current issue of
BS5449 and BS7074 Part 1.

The charge pressure must not be less than the static head of the
system, that is, the height of the highest point of the system
above the expansion vessel.

The water content of the boiler is given in the Data Table 1.

(Make-up
alternatives)

3 LITRES (0.66 gals)
MAKE-UP BOTTLE
(if required)

NON-RETURN
VALVE

HEATING

CIRCUIT

AUTO
AIR
VENT

FLOW

RETURN

DRAIN
COCK

BOILER

22mm (min)
BY-PASS WITH
LOCKSHIELD
VALVE

SAFETY
VALVE

5814

AIR
RELEASE
POINT

FILLING POINT

CIRCULATING
PUMP

PRESSURE
GAUGE

EXPANSION
VESSEL

221504A

8

Diagram 2.3SEALED WATER SYSTEM DIAGRAMMATIC LAYOUT

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

2 Water System

2.11 Pressure Gauge

A pressure gauge with a set pointer and covering at least 0 to
4bar (0 to 60lb in2) shall be fitted permanently to the system in
a position where it can be seen when filling the system.

2.12 Domestic Hot Water Cylinder

SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE.
The hot water cylinder must be of the indirect coil type. It must

be suitable for working at a gauge pressure of 0.35bar above
the safety valve setting.

2.13 Water Makeup

Provision should be made for replacing water loss from the
system using a make up bottle or filling loop mounted in a
position higher than the top point of the system, connected
through a non-return valve to the return side of either the
heating circuit or the hot water cylinder.

Alternatively, provision for make up can be made using a filling
loop.

2.14 Filling a Sealed System

Provision for filling the system at low level must be made. Three
methods are shown in diagram 2.4. There must be no permanent
connection to the mains water supply, even through a non­return valve.

METHOD 1 Mains topping up method

ETHOD 1

TEMPORARY
HOSE

SUPPLY
PIPE

HOSE
UNIONS

SUPPLY STOP
VALVE

COMBINED
CHECK VALVE
AND VACUUM
BREAKER

SERVICING
VALVE

METHOD 2 Mains topping up method

METHOD 2

TEMPORARY
HOSE

SUPPLY
PIPE

HOSE
UNIONS

SUPPLY STOP
VALVE

DOUBLE CHECK
VALVE ASSEMBLY

SERVICING
VALVE

0051M

HEATING
SYSTEM

HEATING
SYSTEM

METHOD 3 Cistern filling method

CISTERN

SUPPLY
STOP VALVE

SUPPLY
PIPE

OVERFLOW

SERVICING
VALVE

HOSE
UNIONS

PRESSURE
REDUCING
VALVE

FILLING A SEALED SYSTEM

HEATING
SYSTEM

DOUBLE CHECK
VALVE ASSEMBLY

Diagram 2.4

9

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C

M

3 Boiler Location

3.1 Boiler Location

The boiler may be installed in any room although particular
attention is drawn to the requirements of the current issue of
BS7671 with respect to the installation of a boiler in a room
containing a bath or shower. Any electrical switch or boiler
control using mains electricity should be so situated that it
cannot be touched by a person using the bath or shower.
The electrical provisions of the Building Standards (Scotland)
are applicable to such installations in Scotland.

The boiler must be mounted on a flat wall which is sufficiently
robust to take its total weight, see Data Table 1.

0073

D

D

B

3.2 Boiler Clearances

The boiler must be positioned so that at least the minimum
operational and servicing clearances are as shown in diagram

3.2.
Additional clearance may be required around the boiler for

installation purposes, dependant upon site conditions.

3.3 Timber Frame Buildings

If the boiler is to be installed in a timber frame building, it should
be fitted in accordance with the British Gas Publication “Guide
for Gas Installation in Timber Framed Housing” reference DM2.
If in doubt, seek advice from the local gas undertaking or
Hepworth Heating Ltd.

3.4 Room Ventilation

The boiler is room sealed, so when installed in a room or space
a permanent air vent is not required.

3.5 Cupboard or Compartment Ventilation

Where the boiler is fitted in a cupboard or compartment,
permanent high and low level ventilation must be provided. The
ventilation areas required are given in Table 5.

Where the installation of the boiler will be in an unusual location,
special procedures are necessary, refer to the current issue of
BS6798 for guidance.

Make sure that 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 specifically for this purpose.

An existing cupboard or compartment modified for the purpose
may be used. Refer to the current issue of BS6798 for
guidance.

The doorway opening should be of sufficient size to allow for
easy removal of the boiler.

E

E

A

PERMANENT
SURFACE

MINIMUM CLEARANCES

A
B
C
D
E

500

78

*

10

5

To a permanent surface
SIDE FLUE - 220mm

*

REAR FLUE - 120mm

*

WHERE EXTERNAL ACCESS TO
THE FLUE IS NOT PRACTICAL THEN
CLEARANCE OPPOSITE THE EXIT
MUST BE ADEQUATE TO PERMIT
INSTALLATION OF THE FLUE ASSEMBLY

CLEARANCES

TABLE 5. COMPARTMENT AIR VENTS

VENTILATION
REQUIREMENTS

HIGH LEVEL LOW LEVEL

VENT AREA VENT AREA

2

cm

Diagram 3.1

2

in

cm

2

2

in

221504A

10

VENTILATION
FROM ROOM
OR SPACE

VENTILATION
FROM
OUTSIDE

195 30 195 30

98 15 98 15

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4 Flue

4.1 Flue

The flue must be installed in accordance with the current issue
of BS5440 Part 1.

The air and flue duct connect to the top of the boiler using an
elbow which can be positioned to the sides or rear.

The standard flue is able to provide the duct lengths ranges
shown in diagram 4.2 rear flue and 4.3 side flue.

If a longer flue duct is required, do not extend the ductings.
A 1,2 and 3m flue system and terminal can be supplied. This is

able to provide the duct length range as shown in diagram 4.2
for a rear flue, diagram 4.3 for a side flue.

4.2 Terminal Position

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

4.1.
The boiler must be installed so that the terminal is exposed to

the external air.
It is important that the position of the terminal allows the free

passage of air across it at all times.
Car ports or similar extensions of a roof only, or a roof and one

wall require special consideration with respect to any openings,
doors, vents or windows under the roof. Care is required to
protect the roof if it is made of plastic sheeting.

If the car port comprises of a roof and two or more walls, seek
advice from the local gas company before installing the boiler.

Where the terminal is fitted within 600mm (24in) below plastic
guttering an aluminium shield 1500mm (5ft) long should be
fitted to the underside and immediately beneath the guttering or
eaves.

Where the terminal is fitted within 450mm (18in) below eaves or
painted guttering an aluminium shield 750mm (2ft6in) long
should be fitted to the underside and immediately beneath the
guttering or eaves.

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
a minimum of 50mm clearance from any part of the terminal and
be central over the terminal, see diagram 4.1.

A suitable terminal guard can be obtained from:

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

their reference K3.

A

A

F

G

UNDER CAR PORT etc.

B,C

G

A

E

G

H,I

B,C

K

F

F

G

J

C

K

L

L

K

G

D

F

K

MINUMUM SITING DIMENSIONS FOR
FANNED FLUE TERMINALS

POSITION

MINIMUM
SPACING

A DIRECTLY BELOW AN OPENABLE mm

WINDOW, AIR VENT, OR ANY OTHER

VENTILATION OPENING 300
B BELOW GUTTER, DRAIN/SOIL PIPE 75
C BELOW EAVES 200
D BELOW A BALCONY OR CAR PORT 200
E FROM VERTICAL DRAIN PIPES AND

SOIL PIPES 75
F FROM INTERNAL OR EXTERNAL 300

CORNERS
G ABOVE ADJECENT GROUND OR

BALCONY LEVEL 300
H FROM A SURFACE FACING THE

TERMINAL 600
I FACING TERMINALS 1200
J FROM OPENING (DOOR/WINDOW) IN

CAR PORT INTO DWELLING 1200
K VERTICAL FROM A TERMINAL 1500
L HORIZONTALLY FROM A TERMINAL 300

2816

11

0161M

Diagram 4.1

221504A